Settler with a settler plate that includes a hollow support

ABSTRACT

The present disclosure relates to settler plates for a plate settler. The settler plates generally include a hollow support with a hollow interior to receive clarified liquid from a flow channel between adjacent settler plates. An orifice is formed through the hollow support to direct clarified liquid from the flow channel into the hollow interior. The orifice can be positioned such that clarified liquid can flow upwardly out of the flow channel and downwardly through the orifice into the hollow interior. The hollow support can be integrally formed with the settler plate. For example, the hollow support can be formed by bending a tab extending from an end of the settler plate. The tab can be bent into a hollow support with a cross section that is generally polygonal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.17/360,767, filed on Jun. 28, 2021, which issued as U.S. Pat. No.11,628,383 on Apr. 18, 2023, which is a Continuation of U.S. patentapplication Ser. No. 16/862,352, filed on Apr. 29, 2020, which issued asU.S. Pat. No. 11,045,749 on Jun. 29, 2021, which is aContinuation-in-Part application and claims the benefit and priority ofU.S. patent application Ser. No. 16/208,262, filed Dec. 3, 2018, issuedas U.S. Pat. No. 10,881,988, entitled “Settler with a Settler Plate thatIncludes a Hollow Support,” and also claims the benefit of CanadianPatent Application No. 3,062,774 filed Nov. 27, 2019, which are eachincorporated herein in their entirety by reference.

FIELD

The present disclosure relates to apparatus and methods for promotingsettling of solids from waste-water, and more particularly to a settlerthat includes settler plates. Each settler plate is provided with ahollow support for clarified liquid flowing from an individual flowchannel defined by adjacent settler plates. The hollow support can beintegrally formed with the settler plate.

BACKGROUND

Clarifiers (also known as “settlers” or “plate settlers”) are used toremove certain materials and particles from liquid or waste-water. Thesematerials are generally suspended in the liquid and can be removed underthe force of gravity when the flow of the liquid is substantiallyreduced, as in a very low flow, or quiescent zone in the clarifier. Thequiescent zone can be within a flow channel of the clarifier. Sincethese materials are generally solid and are said to “settle” out of theliquid, they are referred to as “settleable solids”. Such settleablesolids may include any undesired material including naturally occurringmaterials (e.g., clay, silts, sand and dirt), chemical precipitants andbiological solids or waste products. The word “solids” as used hereinrefers to such settleable solids.

Clarifiers are used, for example, in water and wastewater treatmentplants. In water treatment, the water drawn from a water supply hasvarious non-settleable colloidal solids therein. When mixed withchemicals, the colloidal solids and chemicals agglomerate to formsolids. In wastewater treatment, the solids include organic solids,among other wastes. Water and wastewater are treated in clarifiers toremove such solids, thereby making the water clear and suitable for use,reuse, or for further treatment, such as tertiary treatment. The word“liquid” as used herein refers to water and wastewater.

An object of water and wastewater clarifiers is to create quiescentzones having low flow rates to promote maximum settlement of solids tothe bottom of the clarifiers. Clarifiers typically include a largedetention basin where the settlement of the solids occurs. Flat platesmounted at fixed angles relative to the surface of the liquid have beenused to form multiple thin liquid flow channels. The plates can be heldin the clarifier by supports which are generally connected to the topsof the plates, for example, by welding the supports to the plates.Adjacent supports attached to a pair of adjacent plates define a flowchannel within the detention basin in an attempt to promote settling ofsolids. The liquid containing the solids flows upwardly in the flowchannels between the plates at flow rates that generally allowsufficient time for most of the solids to settle onto the plates.Ideally, the solids then slide down the plates to the bottom of thedetention basin for collection. After the solids have settled, theliquid without the settled solids is referred to as the “clarifiedliquid”. The clarified liquid flows upwardly past the tops of the platesand the supports from each of the separate flow channels and combines toform one or more common volumes of clarified liquid above the tops ofthe plates and the supports. Thus, the clarified liquid from theseparate flow channels may commingle and mix in the common volumes. Thecommon volumes of clarified liquid generally flows to an outlet at alateral end of the plates and exits the basin.

As an example, U.S. Pat. No. 4,889,624 describes plates that aresupported by a frame to define separate flow channels of a clarifier.Each flow channel is defined by adjacent plates. Tops of the plates areprovided with legs that tend to close the upper end of each of the flowchannels. To allow the clarified liquid to flow out of the flowchannels, orifices are provided in settling surfaces of the plates. Theclarified liquid flowing out of one flow channel flows through theorifices of that channel, rises and joins clarified liquid flowing outof the other flow channels. Then the clarified liquid from all of theflow channels flows laterally over the edge of the frame to an outlettrough of the basin. U.S. Pat. No. 4,889,624 is incorporated herein byreference in its entirety.

Another clarifier system is described in U.S. Pat. No. 7,850,860 whichis incorporated herein by reference in its entirety. The clarifiersystem of the '860 patent includes angular support members which areattached to settling surfaces of plates. The angular support memberssupport the plates in the clarifier system such that adjacent platesdefine an upward flow channel with a settling surface there between. Anangular support member of a plate is positioned to define a gap spacedfrom a settling surface of an adjacent plate. Adjacent angular supportmembers define a v-shaped lateral flow channel for each upward flowchannel. A weir assembly includes v-notches associated with eachv-shaped lateral flow channel. The v-notches of the weir assemblyinclude vertexes that are higher than the angular support members suchthat the plates are submerged beneath the weir assembly during operationof the clarifier system. Accordingly, clarified liquid flowing out ofthe channels builds up above the channels until it flows through thev-notches of the weir assembly.

Another example of a clarification system is generally described in U.S.Pat. No. 8,585,896 which is incorporated herein by reference in itsentirety. The clarification system includes inclined settling platesthat rest upon support members. Adjacent settling plates define flowchannels for liquid. The settling plates include an upper flange that isconfigured to contact an adjacent settling plate closing the upper endsof the flow channels. The liquid passes out of the channels throughorifices formed in a body or the flange of the settling plates and thenflows to an effluent trough.

Some of the supports in these clarifiers are welded or otherwiseattached to the settling plates. Attaching the supports to the settlingplates in this manner increases the time and expense required tofabricate the settling plate. Further, the weld or attachment betweenthe settling plate and the support may fail due corrosion that resultsfrom immersion in water.

Additionally, the supports used with some of the settling plates arerelatively weak. More specifically, some prior art supports do not havesufficient strength to permit operators to walk on upper ends of theplates for installation, inspection and maintenance. Accordingly,accessing plates of some prior art settlers is difficult, increasing thetime required by operators to install, inspect, and service prior artsettlers.

In many prior art clarifiers, the clarified liquid flowing from eachchannel defined by adjacent plates joins together in a common volumeabove the plates. The clarified liquid then flows laterally to an outletof the basin. This type of clarifier concentrates the flow of clarifiedliquid at an exit point at one or both of the lateral sides of theplates and can create uneven liquid velocities within the channelsacross the widths of the plates. More specifically, the liquid may flowupwardly faster near the lateral sides of the plates. The flow of liquidmay decrease toward the middle of the plates as clarified liquidcollects above the middle of plates. This uneven flow of liquid and thereduced liquid velocity can decrease the efficiency of the clarifier.Another problem that arises when the clarified liquid from multiplechannels joins into a common volume is that it is difficult, orimpossible, to isolate liquid from one channel for testing to determinethe performance of the channel and whether plates defining the channelrequire maintenance or replacement.

Still another problem with prior art settler plates is that the positionof a support associated with a settler plate may disrupt or alter theflow of liquid within a flow channel. For example, in some prior artsettler plates, a support element is joined or attached to the settlingsurface of the settler plate. Other prior art settler plates include asupport element that projects at least partially above the settlingsurface. Liquid flowing upwardly in the flow channel must alterdirection to flow around the support element. This can create turbulenceor eddies within the flow channel and can disrupt the upward flow of theliquid decreasing the efficiency of the settler plate.

Accordingly, there is a need for an improved settler plate and systemsand methods of positioning settler plates within a clarifier whichreduce or eliminate one or more of the disadvantages of prior artsettler plates.

SUMMARY

One aspect of the present disclosure is a hollow support that does notdisrupt the flow of liquid along a settling surface of a settler plate.The hollow support can be positioned such that the hollow support doesnot project above the settling surface. In one embodiment, the hollowsupport is integrally formed with the settler plate. The hollow supportcan extend from a back surface of the settler plate, the back surfacebeing opposite to the settling surface.

Another aspect of the present disclosure is a settler plate for aclarifier. The settler plate includes a support with a hollow interior.The support can be integrally formed with the settler plate. In oneembodiment, the support can be formed by rolling or bending a portion ofthe settler plate one or more times.

The hollow interior of the support is configured to collect clarifiedliquid from a channel of the clarifier. More specifically, the settlerplate includes an inlet or orifice for clarified liquid to flow from thechannel into the hollow interior within the support.

In one embodiment, the orifice is positioned to collect a substantialamount, if not all, of the flow of the clarified liquid from the channelwithout mixing of the flow with clarified liquid from other channels ofthe clarifier. As a result, the flow of clarified liquid from a flowchannel can be substantially, or completely, isolated. Accordingly, inone embodiment, the flow from the channels of the clarifier can beindividually sampled for examination of the performance of the separateflow channels. If too many solids are identified in liquid from achannel, one or both of the settler plates that define the channel canbe removed from the clarifier for service or replacement. In thismanner, it is possible to identify individual channels and theassociated settler plates than require cleaning or replacement.

Another aspect of the present disclosure is to provide a settler platewith sufficient strength to support a technician. The settler plateincludes a settling surface that is generally rectangular. A hollowsupport is positioned proximate to an upper end of the settler plate.The hollow support can be integrally formed with the settler plate. Thehollow support is configured to receive clarified liquid from a channelformed between the settler plate and an adjacent settler plate.Clarified liquid within the hollow support can be directed laterallywithin the hollow support to a trough.

In one embodiment, the hollow support is formed by bending or rolling anend tab of the settler plate. The hollow support can have any shape. Inone embodiment, the hollow support has a cross-section that is generallyround. Optionally, the hollow support can have two or more sides such asa regular or irregular polygon. For example, the hollow support can havea cross-section that is generally triangular or square. In oneembodiment, the hollow support has a cross-sectional shape of aquadrilateral or four-sided polygon. The hollow support can have across-section of a trapezoid.

The settler plate includes an orifice to direct clarified liquid into ahollow interior of the hollow support. The orifice can be formed at anupper end of the hollow support. Optionally, the orifice can be formedthrough a settling surface of the settler plate. In one embodiment, theorifice is formed through a portion of the hollow support configured toface the adjacent settler plate. In one embodiment, at least one orificeis formed within a middle third of the width of the settling surface. Inthis manner, clarified liquid can enter the hollow support from a medianportion or width of a channel.

In one embodiment, the hollow support is formed such that liquid flowingalong the settling surface of the settler plate does not have to flowaround the hollow support. More specifically, in one embodiment, thehollow support does not project in front of the settling surface. Thehollow support can be formed to extend from a back surface of thesettler plate.

A flange or baffle is provided at each lateral side of the settlerplate. The baffle can be integrally formed with the settler plate. Forexample, in one embodiment, the baffle is formed by bending a lateraltab of the settler plate. A distal portion of the baffle is configuredto contact a settling surface of the adjacent settler plate. In oneembodiment, the baffle defines a distance separating the settler platefrom the adjacent settler plate. In this manner, the baffle can define aheight of a channel between the settler plate and the adjacent settlerplate.

A port for effluent can be formed through the baffle. The port can beformed proximate to the settling surface of the settler plate. Morespecifically, in one embodiment, the port is spaced from the distalportion of the baffle. In this manner, the port can be a predetermineddistance from the settling surface of the adjacent settler plate. Forexample, a distance between an upper edge of the port and the settlingsurface can be less than the distance between a lower edge of the portand the distal portion of the baffle. The port can be of any size andshape. In one embodiment, the port is generally rectangular. Optionally,the port is round or oval. Two or more ports can be formed in eachbaffle.

Optionally, a flange is formed at the distal portion of the baffle. Theflange can be substantially parallel to the settling surface. In oneembodiment, the flange extends inwardly from the distal portion andunder the settling surface of the settler plate. The flange can beformed by a second bend of the lateral tab of the settler plate

A stiffening feature can extend from a lower end of the settler plate.The stiffening feature can be integrally formed with the settler plate.In one embodiment, the stiffening feature is formed by rolling orbending a lower tab of the settler plate. The stiffening feature can beconfigured to contact a support surface of a basin or frame holding thesettler plate. In one embodiment, the stiffening feature has a generallyrectangular shape. The stiffening feature can optionally include ahollow interior. One or more corners of the stiffening feature can berounded. Alternatively, the stiffening feature can have a generallyround shape. In one embodiment, the stiffening feature is formed byrolling the lower tab into a spiral.

Another aspect of the present disclosure is to provide an apparatus forclarifying liquid in which solids are suspended. The apparatus generallyincludes one or more of: (1) a clarifier for containing the liquid andthe solids; and (2) a pair of settler plates spaced along a longitudinalaxis of the clarifier to define a channel, each of the settler platesincluding a settling surface, a baffle at a lateral side, a stiffeningfeature at a lower end, and a hollow support proximate to an upper end,the hollow support integrally formed with the settler plate andincluding at least two segments, a hollow interior, and an orifice forliquid flowing from the channel to enter into the hollow interior, thehollow interior configured to direct liquid to a trough of theclarifier. The pair of settler plates can be positioned in the clarifierat a predetermined angle. Optionally, the settler plates can bepositioned such that the settling surfaces are inclined at an angle ofbetween approximately 30° and approximately 40° to a vertical axis.

In one embodiment, the hollow support is not welded to the settlerplate. The hollow support can be formed by bending a tab extending fromthe settler plate at least two times.

Accordingly, the hollow support and the settler plate can be formed froma single piece of metallic material. In one embodiment, the hollowsupport extends away from a plane defined by the settling surface. Theplane can be in contact with the settling surface. Accordingly, in oneembodiment, the hollow support does not contact the plane.

In one embodiment, the at least two segments of the hollow supportinclude a first segment extending away from the settling surface, asecond segment extending from the first segment, and a third segmentextending from the second segment toward a back surface of the settlerplate. The first segment is joined to the upper end of the settler plateat a first vertex. A first interior angle of the hollow support betweenthe back surface and the first segment can be greater than 90°. Thefirst interior angle can be between approximately 115° and approximately140°. In one embodiment, the first interior angle is selected such thatthe first segment is approximately horizontal when a settler plate ispositioned in the clarifier. A first radius of curvature can be formedbetween the upper end of the settler plate and the first segment. In oneembodiment, the first radius of curvature is between approximately 2/16(or ⅛) inches and 4/16 (or ¼) inches.

A second interior angle between the first segment and the second segmentcan be between approximately 80° and 100°, or approximately 90°. Asecond radius of curvature between the first segment and the secondsegment can be between approximately 2/8 (or ¼) inches and 4/8 (or ½)inches.

Additionally, or alternatively, a third interior angle between thesecond segment and the third segment is between approximately 80° and100°, or approximately 90° in one embodiment. The third segment can beoriented relative to the second segment such that the third segment isapproximately horizontal when the settler plate is positioned in theclarifier. Optionally, the third segment can be approximately parallelto the first segment. The hollow support can have a third radius ofcurvature between the second segment and the third segment. The thirdradius of curvature can be between approximately 1/32 inches and 5/32inches.

Optionally, the hollow support can further include a fourth segmentextending from the third segment. The fourth segment can extend towardthe first segment within the hollow interior of the hollow support. Inone embodiment, the fourth segment can be approximately parallel to theback surface of the settler plate. Additionally, or alternatively, thefourth segment can contact the back surface. Optionally, the fourthsegment is joined to the back surface. For example, the fourth segmentcan be joined to the back surface by mechanical fastener. The mechanicalfastener can be a rivet or a similar fastener. In one embodiment, atleast one rivet extends from the settling surface of the settler platethrough fourth segment of the hollow support.

The hollow support can optionally include a fifth segment extending fromthe fourth segment. The fifth segment includes a free end extending intothe hollow interior of the hollow support.

One or more of the first, second, third, fourth, and fifth segments canbe generally planar. Optionally, at least one of the first through fifthsegments is not planar. For example, at least one of the first, second,third, fourth, and fifth segments can have a curved or arched surface.

The orifice is positioned such that at least some liquid can enter thehollow interior through the orifice before moving laterally to thetrough. The trough is positioned proximate to at least one lateral sideof the settler plate. The orifice can be positioned such that liquid canflow upwardly past an upper end of the settling surface and thendownwardly through the orifice into the hollow interior of the hollowsupport. In one embodiment, the orifice is formed through the firstsegment of the hollow support. Optionally, the hollow support caninclude a plurality of orifices. At least one of the plurality oforifices can be formed in a medial portion of the hollow support. Eachof the orifices can have a shape that is selected from a circle, atriangle, a square, and a rectangle.

The stiffening feature can be integrally formed with the settler platefrom a single piece of metallic material. For example, the stiffeningfeature can be formed by bending a lower tab extending from a lower endof the settler plate. The lower tab can be bent or folded two or moretimes to form the stiffening feature. In one embodiment, a first segmentof the lower tab is bent or folded back at an angle of approximately180° toward a second segment of the lower tab to form the stiffeningfeature. In this manner, the first segment of the stiffening feature isapproximately parallel to the second segment of the stiffening feature.A free end of the first segment can be oriented toward the back surfaceof the settler plate.

The stiffening feature can be angled away from the settling surface. Inone embodiment, the stiffening feature is oriented at an angle ofbetween approximately 25° and approximately 55° below the settlingsurface.

The baffle can include a flange. The flange can be oriented at an angleof at least approximately 90° to the baffle. In one embodiment, theflange is approximately parallel to the settling surface. The flange ofa first one of the pair of settler plates is configured to contact asettling surface of a second one of the pair of settler plates. In oneembodiment, a free end of the baffle is angled away from the settlingsurface. In this manner, when the flange of the first one of the settlerplates contacts the settling surface of the second one, the flange canapply a biasing force to the settling surface to form a seal to preventthe flow of liquid between the flange and the settling surface.

One aspect of the present disclosure is to provide apparatus forclarifying liquid in which solids are suspended, comprising: (1) aframe; and (2) a plurality of settler plates spaced along a longitudinalaxis of the frame to define a plurality of channels, each of the settlerplates including a settling surface, a baffle at a lateral side, astiffening feature at a lower end, and a hollow support proximate to anupper end, the hollow support integrally formed with the settler plateand including a hollow interior and an orifice for liquid flowingupwardly from a channel to enter into the hollow interior, the hollowinterior configured to direct liquid laterally to a trough. In oneembodiment, the settler plate and the hollow support are formed from asingle piece of a stainless steel alloy without welding.

The orifice can be positioned such that liquid can flow upward past theupper end and then downward through the orifice into the hollowinterior. In this manner at least some liquid can enter the hollowinterior through the orifice before moving laterally to the trough.

The hollow support can include a first segment extending away from thesettling surface, a second segment extending from the first segment, anda third segment extending from the second segment toward a back surfaceof the settler plate. In one embodiment, the first segment extends awayfrom a plane defined by the settling surface at an angle of betweenapproximately 50° and approximately 60°. The second segment can extendfrom the first segment at an angle of between approximately 80° and100°. Additionally, the third segment may extend from the second segmentat an angle of between approximately 80° and approximately 100°.

Optionally a first radius of curvature between the upper end of thesettler plate and the first segment can be between approximately ⅛inches and ¼ inches. Additionally, a second radius of curvature betweenthe first segment and the second segment may be between approximately ¼inches and ½ inches. In one embodiment, a third radius of curvaturebetween the second segment and the third segment is betweenapproximately 1/32 inches and 5/32 inches.

The hollow support optionally can include a fourth segment extendingfrom the third segment, the fourth segment being approximately parallelto the back surface. In one embodiment, the fourth segment is joined tothe back surface.

The baffle can include a flange. A flange of a first settler plate isconfigured to contact a settling surface of a second adjacent settlerplate.

In one embodiment, the frame is configured to receive at least 30settler plates. Each settler plate can be fixed to the frame with thesettling surface inclined upwardly at an angle of between approximately50° and 65° relative to a horizontal axis of the frame.

It is another aspect of the present disclosure to provide a settlerplate for a plate pack, comprising: (1) a settling surface that isgenerally rectangular; (2) a baffle at a lateral side of the settlerplate; (3) a stiffening feature at a lower end of the settler plate; (4)a hollow support extending from a back surface of the settling surface,the hollow support having a hollow interior configured to transportliquid laterally; and (5) an orifice for liquid to enter the hollowsupport. The settling surface can be substantially planar. Optionally,the hollow support can have a width that is greater than a width of thesettling surface. In one embodiment, the hollow support extends awayfrom a plane defined by the settling surface. The plane can be incontact with the settling surface. Accordingly, in one embodiment, thehollow support does not contact the plane.

The hollow support can be integrally formed with the settler plate. Forexample, the hollow support can be formed by bending or folding a tabextending from an end of the settling surface. The tab can be bent twoor more times to form the hollow support. The hollow support and thesettler plate can be formed from a single piece of a metallic material.

The hollow support has a cross-sectional shape that can be one of acircle, an ellipse, a triangle, a square, a rectangle, and a polygonwith three, four, five or more sides. The hollow support can include afirst segment extending away from the settling surface, a second segmentextending from the first segment, and a third segment extending from thesecond segment toward the back surface of the settler plate.

The first segment has a first length, the second segment has a secondlength, and the third segment has a third length. The first length canbe less than the second length. The second length can be less than thethird length.

In one embodiment, a first interior angle between the settling surfaceand the first segment is between approximately 115° and approximately135°. In another embodiment, the first segment is oriented such thatwhen the settling surface of the settler plate is inclined at an angleof between approximately 30° and 35° relative to a vertical axis thefirst segment will be approximately horizontal. A second interior anglebetween the first segment and the second segment can be betweenapproximately 80° and approximately 100°. The hollow support can alsoinclude a third interior angle between the third segment and the secondsegment. The third interior angle can be between approximately 80° andapproximately 100°. Optionally, the third segment can be approximatelyparallel to the first segment.

A first radius of curvature can be formed between the settling surfaceand the first segment. In one embodiment, the first radius of curvatureis between approximately 2/16 (or ⅛) inches and 4/16 (or ¼) inches. Asecond radius of curvature between the first segment and the secondsegment can be between approximately 2/8 (or ¼) inches and 4/8 (or ½)inches. In one embodiment, the hollow support has a third radius ofcurvature between the second segment and the third segment. The thirdradius of curvature can be between approximately 1/32 inches and 5/32inches.

The hollow support can further include a fourth segment extending fromthe third segment. The fourth segment can be oriented toward the firstsegment. Optionally, the fourth segment is generally parallel to thesettling surface. In one embodiment, the fourth segment contacts theback surface. The fourth segment optionally is joined to the backsurface. For example, a mechanical fasten can extend through the settingsurface into the fourth segment. The mechanical fastener can be a rivet.

Additionally, the hollow support can include a fifth segment. The fifthsegment can extend from the optional fourth segment into the hollowinterior. In one embodiment, the fifth segment is oriented transverse tothe first segment.

One or more of the first, second, third, fourth, and fifth segments canbe generally planar. Optionally, at least one of the first through fifthsegments is not planar. For example, at least one of the first, second,third, fourth, and fifth segments can have a curved or arched surface.

The stiffening feature can be integrally formed with the settler plate.For example, the stiffening feature can be formed by bending a lower tabextending from a lower end of the settling surface. The lower tab can bebent two or more times to form the stiffening feature. In oneembodiment, a free end of the lower tab is bent back at an angle ofapproximately 180° to form the stiffening feature. In this manner, afirst segment of the stiffening feature is generally parallel to asecond segment of the stiffening feature. A free end of the lower tabcan be oriented toward the back surface of the settling surface.

The stiffening feature can be oriented at an angle relative to the planedefined by the settling surface. In one embodiment, the stiffeningfeature is oriented at an angle of between approximately 25° andapproximately 55° below the plane defined by the settling surface.

Still another aspect of the present disclosure is to provide a method offorming a settler plate. The method includes, but is not limited to, oneor more of: (1) providing a blank including a first end tab, a secondend tab, and lateral tabs; (2) folding or bending the first end tab atleast two times to form a hollow support that extends from a backsurface of the settler plate; (3) folding or bending the second end tabat least two times to form a stiffening feature at a lower end of thesettler plate; and (4) folding or bending the lateral tabs to form abaffle at each lateral side of the settler plate. The blank can be astainless steel alloy.

Folding the first end tab can include forming the hollow support into apolygonal shape. For example, in one embodiment folding the first endtab further comprises: (i) forming a first segment of the hollow supportthat extends away from the back surface; (ii) forming a second segmentthat extends away from the first segment; and (iii) forming a thirdsegment that extends from the second segment and toward the backsurface. The first segment can extend from the back surface at an angleof between approximately 115° and approximately 140°. A first radius ofcurvature can be formed between the back surface of the settler plateand the first segment. The first radius of curvature can be betweenapproximately 2/16 (or ⅛) inches and 4/16 (or ¼) inches.

The second segment may extend from the first segment at an angle ofbetween approximately 80° and 100°. A second radius of curvature betweenthe first segment and the second segment can be between approximately2/8 (or ¼) inches and 4/8 (½) inches.

Optionally, forming the second segment can include: (a) folding thefirst end tab to form a first angle between the second segment and thethird segment; (b) forming the first segment; and (c) altering the firstangle between the second segment and the third segment. In oneembodiment, the first angle is approximately 135°. Optionally, the firstangle is decreased to approximately 90° after the angle is altered.

The third segment can extend from the second segment at an angle ofbetween approximately 80° and approximately 100°. The first and thirdsegments can be approximately parallel. In one embodiment, a thirdradius of curvature is formed between the second segment and the thirdsegment. The third radius of curvature can be between approximately 1/32inches and 5/32 inches.

The method can include forming a fourth segment that extends from thethird segment. The fourth segment can be oriented generally parallel tothe back surface. Optionally, the method can further include joining thefourth segment to the back surface. In one embodiment, the joiningincludes driving a mechanical fastener through the fourth segment andthe back surface. The mechanical fastener can be a rivet.

The method may further include folding the lateral tabs to form a flangeat a distal end of each of the baffles. In one embodiment, the flangescan extend approximately parallel to the back surface. In anotherembodiment, each flange is oriented at an angle of at least 90° to anassociated baffle.

In one embodiment, the blank comprises a planar central sheet that isgenerally rectangular. The central sheet can include a first narrow end,a second narrow end, and two lateral sides. The first end tab can extendfrom the first narrow end, the second end tab can extend from the secondnarrow end, and a lateral tab can extend from each of the two lateralsides. The blank can also include a notch formed between each of thelateral tabs and the first end tab. Additionally, or alternatively, amitered notch can be formed between each of the lateral tabs and thesecond end tab.

The first end tab can be wider than the second end tab. Optionally, thecentral sheet is wider than the second end tab. Additionally, oralternatively, the central sheet can be longer than the lateral tabs.

It is another aspect of the present disclosure to provide an apparatusfor clarifying liquid in which solids are suspended. The apparatuscomprises: (1) a frame; and (2) a plurality of settler plates spacedalong a longitudinal axis of the frame to define a plurality ofchannels, each of the settler plates including: (a) a settling surface;(b) a back surface; (c) a baffle at a lateral side of the settlingsurface, the baffle extending upwardly above the settling surface; (d) astiffening feature at a lower end; and (e) a hollow support proximate toan upper end that is integrally formed with the settling surface, thehollow support extending upwardly above the settling surface andincluding a hollow interior and an orifice for liquid flowing upwardlyfrom a channel to enter into the hollow interior, the hollow interior todirect liquid laterally to a trough.

In one embodiment the hollow support further comprises a first segmentextending from the settling surface.

In one embodiment the hollow support further comprises a second segmentextending from the first segment.

In one embodiment the hollow support further comprises a third segmentextending from the second segment toward the baffle.

Optionally, the third segment is oriented at an oblique angle to thesecond segment.

In one embodiment the hollow support further comprises a fourth segmentextending from the third segment and proximate to an end of the baffle.

The fourth segment is optionally oriented at an oblique angle to thethird segment.

In one embodiment the hollow support further comprises a fifth segmentextending from the fourth segment, the fifth segment extending along aportion of the first segment.

Optionally, two of the segments are oriented approximately perpendicularto each other.

In one embodiment, the second segment is approximately perpendicular tothe first segment.

Additionally, or alternatively, the fourth segment is optionallyoriented approximately perpendicular to one or more of the first segmentand the fifth segment.

In one embodiment, the fourth segment is approximately parallel to thesecond segment.

In one embodiment, the fifth segment is approximately parallel to thefirst segment.

Optionally, the hollow support includes a fastener extending through twoof the segments.

In one embodiment, the fastener extends through the first and fifthsegments.

Optionally, the orifice extends through an uppermost portion of thehollow support.

In one embodiment, the uppermost portion of the hollow support isoriented approximately horizontally when the settler plate is positionedin the frame.

In one embodiment, the orifice extends through the second segment.

In one embodiment, an interior angle between the settling surface andthe first segment is between approximately 130° and approximately 160°.

In one embodiment, the hollow support does not intersect a plane definedby the back surface.

In one embodiment, the settler plate and the hollow support are formedfrom a single piece of a stainless steel alloy

In one embodiment, the settler plate and the hollow support are formedwithout welding.

In one embodiment, the baffle includes a flange that extends above thesettling surface

In one embodiment, a flange of a first settler plate contacts a backsurface of a second adjacent settler plate.

In one embodiment, the baffle includes a port formed proximate to alower end of the baffle.

In one embodiment, the port has a shape that is generally circular,rectangular, or square.

In one embodiment, the settler plates are inclined at an angle ofbetween approximately 50° and approximately 60° relative to thelongitudinal axis of the frame.

It is another aspect of the present disclosure to provide a settlerplate, comprising: (1) a settling surface that is substantiallyrectangular; (2) a back surface opposite to the settling surface; (3) abaffle at a lateral side of the settler plate; (4) a stiffening featureat a lower end of the settler plate; and (5) a hollow support at anupper end of the settler plate, the hollow support extending from thesettling surface and including: (a) a hollow interior to transportliquid laterally; (b) a width that is greater than a width of thesettling surface; and (c) an orifice for liquid to enter the hollowsupport.

In one embodiment, the hollow support is integrally formed with thesettler plate.

In one embodiment, the settler plate is formed from a single piece of astainless steel alloy.

In one embodiment, the settle plate is formed without welding.

In one embodiment, the baffle extends upwardly above the settlingsurface.

In one embodiment, the baffle includes a port formed proximate to alower end of the baffle.

In one embodiment, the port has a shape that is generally circular,rectangular, or square.

In one embodiment, the baffle includes a flange that extends above thesettling surface

In one embodiment, the flange is configured to contact a back surface ofa second adjacent settler plate.

Optionally, the orifice extends through an uppermost portion of thehollow support when the settler plate is in a position of use.

In one embodiment, the uppermost portion of the hollow support isoriented approximately horizontally when the settler plate is in theposition of use.

In one embodiment, the hollow support is formed by bending a piece ofthe settler plate at least four times.

In one embodiment, the hollow support comprises a first segmentextending from the settling surface.

In another embodiment, the first segment is the uppermost portion of thehollow support when the settler plate is in the position of use.

In one embodiment, an interior angle between the settling surface andthe first segment is between approximately 130° and approximately 160°.

In one embodiment, the hollow support further comprises a second segmentextending from the first segment.

In one embodiment, the second segment is oriented approximatelyperpendicular to the first segment.

In one embodiment, the orifice is formed through the second segment.

In one embodiment, a third segment extends from the second segmenttoward the baffle.

The third segment is optionally oriented at an oblique angle relative tothe second segment.

In one embodiment, an interior angle between the second segment and thethird segment is between approximately 115° and approximately 121°.

In one embodiment, a fourth segment extends from the third segment andproximate to an end of the baffle.

In one embodiment, the fourth segment is oriented approximately parallelto the second segment.

The fourth segment is optionally oriented at an oblique angle relativeto the third segment.

In one embodiment, an interior angle between the third segment and thefourth segment is between approximately 59° and approximately 65°.

In one embodiment, a fifth segment extends from the fourth segment.

In one embodiment, the fourth segment is approximately perpendicular toone or more of the first segment and the fifth segment.

Optionally, the hollow support includes a fastener extending through twoof the segments.

In one embodiment, the fifth segment is joined to the first segment by afastener.

Still another aspect is to provide a method of forming a settler plate,comprising: (1) providing a blank of a metallic material, the blankincluding a first end tab, a second end tab, and lateral tabs; (2)bending the first end tab at least two times to form a hollow supportthat extends from a settling surface of the settler plate; (3) bendingthe second end tab at least two times to form a stiffening feature at alower end of the settler plate; and (4) bending the lateral tabsupwardly to form a baffle at each lateral side of the settler plate, thebaffles extending above the settling surface.

In one embodiment, the blank is a stainless steel alloy.

The method may include bending the first end tab upwardly approximately35° to form a first segment of the hollow support, the first segmentextending from the settling surface.

The method may include bending the first end tab upwardly approximately90° to form a second segment of the hollow support that extends from thefirst segment.

The method may include bending the first end tab upwardly betweenapproximately 59° and approximately 65° to form a third segment of thehollow support that extends from the second segment.

The method may include bending the first end tab upwardly betweenapproximately 115° and approximately 121° to form a fourth segment ofthe hollow support that extends from the third segment.

The method may include bending the first end tab upwardly approximately90° to form a fifth segment of the hollow support that extends from thefourth segment.

In one embodiment, the fifth segment is approximately parallel to thefirst segment.

The method may include joining the fifth segment to the first segmentwith a fastener.

The method may include bending the first end tab upwardly to form asixth segment of the hollow support that extends from the fifth segment,the sixth segment defining a free end of the first end tab.

The method may include bending the lateral tabs to form a flange at adistal end of each of the baffles.

In one embodiment, the flanges extend approximately parallel to thesettling surface.

Optionally, the method includes joining two of the segments with afastener.

In one embodiment, the fastener extends through the first segment andthe fifth segment.

The method may further include forming an orifice through the first endtab.

In one embodiment, after bending the first end tab to form the hollowsupport, the orifice extends through the second segment.

The Summary is neither intended nor should it be construed as beingrepresentative of the full extent and scope of the present disclosure.The present disclosure is set forth in various levels of detail in theSummary as well as in the attached drawings and the Detailed Descriptionand no limitation as to the scope of the present disclosure is intendedby either the inclusion or non-inclusion of elements, components, etc.in this Summary. Additional aspects of the present disclosure willbecome clearer from the Detailed Description, particularly when takentogether with the drawings.

The phrases “at least one,” “one or more,” and “and/or,” as used herein,are open-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, Band C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “oneor more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, Calone, A and B together, A and C together, B and C together, or A, B andC together.

Unless otherwise indicated, all numbers expressing quantities,dimensions, conditions, and so forth used in the specification andclaims are to be understood as being modified in all instances by theterm “about” or “approximately.” Accordingly, unless otherwiseindicated, all numbers expressing quantities, dimensions, conditions,ratios, ranges, and so forth used in the specification and claims may beincreased or decreased by approximately 5% to achieve satisfactoryresults. In addition, all ranges described herein may be reduced to anysub-range or portion of the range, or to any value within the rangewithout deviating from the invention.

The term “a” or “an” entity, as used herein, refers to one or more ofthat entity. As such, the terms “a” (or “an”), “one or more” and “atleast one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereofherein is meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Accordingly, the terms “including,”“comprising,” or “having” and variations thereof can be usedinterchangeably herein.

It shall be understood that the term “means” as used herein shall begiven its broadest possible interpretation in accordance with 35 U.S.C.,Section 112(f). Accordingly, a claim incorporating the term “means”shall cover all structures, materials, or acts set forth herein, and allof the equivalents thereof. Further, the structures, materials, or actsand the equivalents thereof shall include all those described in theSummary, Brief Description of the Drawings, Detailed Description,Abstract, and Claims themselves.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the disclosedsystem and together with the general description of the disclosure givenabove and the detailed description of the drawings given below, serve toexplain the principles of the disclosed system(s) and device(s). Thedrawings are not necessarily to scale. In certain instances, detailsthat are not necessary for an understanding of the disclosure or thatrender other details difficult to perceive may have been omitted.

FIG. 1 is a schematic view of a clarifier of one embodiment of thepresent disclosure;

FIG. 2 is a side perspective view of a plate pack including settlerplates of one embodiment of the present disclosure;

FIGS. 3A, 3B are partial views of a frame holding settler plates of thepresent disclosure;

FIG. 4A is a side perspective view of a settler plate of an embodimentof the present disclosure;

FIG. 4B is a back perspective view of the settler plate of FIG. 4A;

FIG. 4C is a side elevation view of the settler plate of FIG. 4A;

FIG. 4D is an end elevation view of the settler plate of FIG. 4A withsome features of the settler plate shown in hidden lines;

FIG. 4E is an expanded side elevation view of a portion the settlerplate illustrating a hollow support of one embodiment of the presentdisclosure;

FIG. 4F is another expanded side elevation view of a portion the settlerplate illustrating a stiffening feature of one embodiment of the presentdisclosure;

FIG. 4G is a partial side elevation view of lower portions of settlerplates of the present disclosure positioned in a clarifier;

FIG. 4H is another partial side elevation view of upper portions ofsettler plates of the present disclosure positioned in the clarifier;

FIG. 4I is a side elevation view similar to FIG. 4H and illustrating anorifice formed in the hollow support according to another embodiment;

FIG. 5 is an elevation view showing the flow of liquid and solids alonga settler plate and clarified liquid flowing into a hollow supportaccording to embodiments of the present disclosure;

FIG. 6 is a side elevation view of a portion of a trough of a clarifierand showing hollow supports retained in a predetermined alignmentrelative to the trough;

FIG. 7 is a partial side elevation view of a settler plate including acylindrical hollow support according to one embodiment of the presentdisclosure;

FIG. 8 is another partial side elevation view illustrating a settlerplate with a triangular hollow support of another embodiment of thepresent disclosure;

FIG. 9 is a top plan view of a blank of the present disclosure that canbe formed into a settler plate of one embodiment;

FIGS. 10A-10F are side elevation views of a portion of the blank of FIG.9 being formed into a hollow support of one embodiment of the presentdisclosure;

FIG. 11 is a perspective view of a plate pack one an embodiment of thepresent disclosure;

FIG. 12 is a side elevation view of the plate pack of FIG. 11 ;

FIG. 13 is an enlarged perspective view of a portion of the plate packof FIG. 11 ;

FIG. 14 is an enlarged side elevation view of the plate pack of FIG. 12;

FIG. 15A is a side perspective view of a settler plate of anotherembodiment of the present disclosure;

FIG. 15B is a top plan view of the settler plate of FIG. 15A;

FIG. 15C is a side elevation view of the settler plate of FIG. 15A;

FIG. 15D is an end elevation view of the settler plate of FIG. 15A withsome features of the settler plate shown in hidden lines;

FIG. 15E is an expanded side elevation view of a portion of the settlerplate of FIG. 15C illustrating a hollow support of one embodiment of thepresent disclosure;

FIG. 15F is another expanded side elevation view of a portion of thesettler plate of FIG. 15C illustrating a stiffening feature of oneembodiment of the present disclosure;

FIG. 15G is a partial side elevation view of upper portions of settlerplates of the present disclosure positioned in a detention basin; and

FIG. 16 is a top plan view of a blank of the present disclosure that canbe formed into a settler plate according to the embodiment of FIG. 15 ;

It should be understood, of course, that the disclosure is notnecessarily limited to the embodiments illustrated herein. As will beappreciated, other embodiments are possible using, alone or incombination, one or more of the features set forth above or describedbelow. For example, it is contemplated that various features and devicesshown and/or described with respect to one embodiment may be combinedwith or substituted for features or devices of other embodimentsregardless of whether or not such a combination or substitution isspecifically shown or described herein.

The following is a listing of components according to variousembodiments of the present disclosure, and as shown in the drawings:

Number Component  2 Clarifier  4 Detention basin  6 Inlet to basin  8Outlet from basin 10 Walls of basin 12 Open top of basin 14 Bottom ofbasin 16 Sections of the basin 18 Partition 20 Longitudinal axis 26Trough 30 Weir 32 Trough inlet 34 Baffle or upper mounting plate 36Recess of baffle 40 Solids 42 Liquid   42C Clarified liquid 44 Arrowindicating flow of liquid and solids 46 Arrow indicating flow ofclarified liquid 47 Arrow indicating movement of solids 48 Liquid level50 Plate pack 51 Frame of plate pack 52 Cover of plate pack 54 Stud 56Channel defining a quiescent zone 58 Outlet of a channel 60 Settlerplate 62 Settling surface 64 Width of settling surface 66 Upper end ofsettler surface 68 Lower end of settler surface 70 Stiffening feature ofsettler plate 71 Flange of stiffening feature 72 Lateral side of thesettler surface 74 Baffle of the settler plate 76 Distal portion ofbaffle 78 Flange of the baffle 80 End of baffle 82 Port for effluent 83Distance between port and settling surface 84 Back surface 86 Rivet ormechanical fastener 90 Hollow support 92 Hollow interior 94 Width ofhollow support 95 Distance between hollow supports  96A First or uppersegment   96B Second segment   96C Third segment or lower segment  96DFourth segment   96E Fifth segment  96F Sixth segment 98 Orifice oraperture into a hollow support 99 Free end 110  Blank 112  Central sheet114  First end tab 116  First bend axis 118  Second bend axis 120  Thirdbend axis 122  Fourth bend axis 124  Fifth bend axis 126  Second end tab128  Sixth bend axis 130  Seventh bend axis 132  Lateral tabs 134 Eighth bend axis 136  Ninth bend axis 138  Notch 140  Notch 142 Projection 144  Rivet position 146  Tenth bend axis 148  Eleventh bendaxis R1 Radius between settling surface and first segment R2 Radiusbetween first segment and second segment R3 Radius between secondsegment and third segment Ω Angle between longitudinal axis and settlerplate

DETAILED DESCRIPTION

Referring to FIG. 1 , a clarifier 2 of one embodiment of the presentdisclosure is shown for removing materials and waste such as solids 40from liquid 42. The clarifier 2 can include outer walls 10 which definea detention basin 4 having an open top 12 and a bottom 14. Oneembodiment of the clarifier 2 is shown in FIG. 1 and has a generallyrectangular shape. However, clarifiers 2 of the present disclosure canhave other shapes, such as square or circular. The basin 4 can bedivided into a number of sections 16. The sections 16 can be defined byan outer wall 10 and, optionally, by an internal partition 18. A portionof the internal partition is illustrated. The clarifier sections 16 canfunction to contain the liquid 42 and the solids 40 within apredetermined portion of the clarifier.

A plurality of settler plates 60 are positioned in the clarifier 2 in aspaced relationship to each other for defining separate channels 56 inwhich the liquid 42 flows upwardly (as indicated by arrow 44) to settlethe solids 40 and provide a clarified liquid 42C. The settler plates 60can be spaced along a longitudinal axis 20 of a partition 18. A hollowsupport 90 is associated with each of the settler plates. A trough 26for clarified liquid 42C can be provided at one or both lateral sides ofeach settler plate 60. The hollow supports 90 can be releasably fixed tothe troughs 26. In this manner, the plurality of settler plates 60 canbe releasably positioned in the clarifier.

As the liquid 42 and the solids 40 flow through the basin 4 from aninlet 6 to outlets 8, the flow of the liquid 42 and the solids 40 issubstantially reduced according to the principles of the presentdisclosure to form many very low flow rate, or quiescent, zones definedby flow channels 56 between adjacent settler plates 60 in the clarifier2. The liquid 42 and the solids 40 flow upwardly (see arrows 44indicating the flow of liquid and solids) in the channels 56 so that thesolids 40 settle out of the liquid 42 and the resulting clarified liquid42C (represented by arrows 46), flows into hollow supports 90 associatedwith the settler plates 60. The clarified liquid 42C flows through thehollow supports 90 to the outlets 8 of the clarifier 2. These outlets 8may be in the form of openings from the troughs 26.

Referring now to FIG. 2 , a plate pack 50 of the present disclosure isgenerally illustrated. The plate pack 50 comprises a plurality ofsettler plates 60 supported by a frame 51. In one embodiment, the platepack 50 includes from approximately eight settler plates 60 toapproximately one hundred twenty settler plates. Optionally, a cover 52can be included with the plate pack 50. The plate pack 50 can beinstalled in a basin 4 with, or in place of, a clarifier section 16 suchas described in conjunction with FIG. 1 .

Referring now to FIGS. 3A, 3B, a portion of a plate pack 50 and twosettler plates 60 of an embodiment of the present disclosure aregenerally illustrated. The settler plates 60 are illustrated having awidth between two lateral sides 72 that is greater than a length definedbetween an upper end 66 and a lower end 68 of the settling surface 62.In other embodiments, the width of the settler plate 60 is less than thelength.

Each settler plate 60 is associated with a hollow support 90. The hollowsupports 90 are configured to carry one settler plate 60 in the frame51. The hollow support can be fastened or affixed to the settler plate.More specifically, the hollow support can be affixed to the settlerplate by a weld, a rivet, a bolt, a screw, a mechanical interlockingattachment, an adhesive, and other known attachment means. In oneembodiment, a mechanical fastener 86 can extend through a portion of thesettler plate, such as the settling surface 62, into the hollow support90. Additionally, or alternatively, in one embodiment a hollow support90 can be integrally formed at an upper end 66 of a settler plate 60.

Adjacent hollow supports 90A, 90B carry respective adjacent settlerplates 60 in a predetermined alignment to define one channel 56.Opposite ends of each hollow support 90 are engaged with a trough (suchas illustrated in FIG. 1 ). This engagement can be removable asdescribed below. Alternatively, the hollow supports 90 can be fixed tothe plate pack 50. Specifically, the hollow support 90 can be joined toa portion of the frame 51, such as a support element or baffle 34, by afastener, a mechanical interlocking attachment, a weld, or other means.

Referring now to FIGS. 4A-4H, settler plates 60 of embodiments of thepresent disclosure are generally illustrated. A settler plate 60includes a settling surface 62 with an upper end 66, a lower end 68, andlateral sides 72. The settling surface 62 can have a shape that isgenerally rectangular and substantially planar. In one embodiment, thesettling surface 62 has a length of between approximately 100 inches andapproximately 130 inches. Optionally, the settling surface has a width64 of between approximately 44 inches and approximately 64 inches. Thesettling surface 62 is generally smooth to facilitate movement of solids40 that collect on the settling surface 62 toward the lower end 68.Optionally, a coating can be added to the settling surface 62 toprevent, or reduce the likelihood, of solids sticking. In oneembodiment, the coating can be a polytetrafluoroethylene (PTFE) (such asTeflon), a silicone, an enamel, or a ceramic.

The settler plate 60 can be made of any suitable material, such as oneor more of stainless steel, fiber reinforced composites, plastic,polyvinyl chloride (PVC), carbon steel, and aluminum. In one embodiment,the settler plate 60 comprises a 304 stainless steel alloy. The materialfrom which the settler plate 60 is formed can have a thickness ofbetween approximately 0.015 inches and 0.035 inches. Optionally, thesettler plate 60 is formed of a 20 to 26 gauge material. In oneembodiment, the settle plate is manufactured from a 24 gauge stainlesssteel alloy.

A hollow support 90 extends from the settler plate 60 proximate to theupper end 66. The hollow support 90 includes a hollow interior 92. Inone embodiment, the hollow support 90 projects or extends away from thesettling surface 62. For example, the hollow interior 92 can bepositioned to extend from a back surface 84 of the settler plate. Morespecifically, the hollow support 90 can be formed such that a planecontacting the settling surface 62 is not interrupted by the hollowsupport. Said differently, the hollow support can be oriented such thatno portion of the hollow support 90 contacts the plane contacting thesettling surface. In one embodiment, the hollow support 90 is formedsuch that liquid 42 can flow upward generally parallel to the settlingsurface to the upper end 66 without obstruction or interference from thehollow support 90. This configuration, which is generally illustrated inFIG. 4E, can improve the flow of liquid 42 along the settling surface62. More specifically, liquid 42 flowing upward proximate to thesettling surface 62 can flow up to and beyond the upper end 66 of thesettling surface without altering direction to flow around the hollowsupport. Accordingly, turbulence in the liquid 42 may beneficially bereduced and efficiency of the settler plate 60 may be improved. Forexample, liquid 42 flowing upwardly proximate to the settling surface 62can be substantially laminar. In contrast, in some prior art settlerssuch as described in U.S. Pat. No. 7,850,860, an angled support isinterconnected to, and extends above a settling surface of an associatedsettling plate. Liquid flowing upwardly in a channel of the '860 patentmust flow around a leg of the support which extends from the settlingsurface of the settling plate. This arrangement may disrupt the upwardflow of liquid and could cause turbulence or eddies in the channel andcan decrease the efficiency of the settler describe in the '860 patent.

A width 94 of the hollow support can be greater than the width 64 of thesettling surface. For example, the width 94 of the hollow support 90 canbe between approximately 46 inches and approximately 66 inches.Accordingly, at least a portion of the hollow support 90 can extendbeyond one or both baffles 74 positioned at the lateral sides 72 of thesettling surface 62 as generally illustrated in FIG. 4D. In oneembodiment, the width 94 of the hollow support 90 is at leastapproximately 3% greater than the width 64 of the settling surface.

In one embodiment, the hollow support 90 is integrally formed with thesettling surface 62. For example, the hollow support 90 can be formed byaltering the shape of a tab 114 extending from the upper end 66 asgenerally described in conjunction with FIGS. 9-10 . The hollow support90 is illustrated in FIG. 4E with four sides including a portion of thesettling surface 62. Optionally, the hollow support 90 can have across-section of a trapezoid. However, the hollow support 90 can haveother configurations with more, or fewer sides. In one embodiment, thetab can be bent or rolled such that the hollow support 90 has across-section that is generally circular. In another embodiment, the tabextending from the upper end 66 can be bent to form a hollow supportwith a triangular or rectangular cross-section. In one embodiment, thehollow support 90 has a cross-sectional shape of a regular or irregularpolygon.

Referring now to FIG. 4E, in one embodiment the hollow support includesa number of segments 96 formed by bending or folding the tab extendingfrom the settling surface 62. For example, the hollow support 90 cancomprise a first segment 96A interconnected to the settling surface 62.A second segment 96B can extend from the first segment. A third segment96C of the hollow support can extend from the second segment 96B. Afourth segment 96D can optionally run from the third segment 96C and beoriented substantially parallel to a back surface 84 of the settlingsurface 62. The fourth segment 96 can contact the back surface 84 in oneembodiment of the present disclosure. Additionally, or alternatively, afifth segment 96E can extend inwardly from an end of the fourth segment96D. The fifth segment 96E is configured to increase the stiffness ofone or more of the fourth segment 96D and of the hollow support 90. Forexample, the fifth segment 96E can increase the stiffness of the hollowsupport 90 such that the settling surface 62 and the fourth segment 96Ddo not bend or deform if a mechanical fastener 86 is added to the hollowsupport. Accordingly, in one embodiment, because of the fifth segment96E, the hollow support 90 can be formed of less (or thinner) materialwithout decreasing the strength of the hollow support, beneficiallyreducing the material expense of the settler plate 60.

The first segment 96A can be oriented at an angle with respect to thesettling surface 62 such that when the settler plate 60 is positioned ina clarifier 2, the first segment 96A will be substantially horizontal asgenerally illustrated in FIG. 4H. Similarly, the third segment 96C canbe formed such that it is substantially horizontal when the settlerplate 60 is positioned in the clarifier 2. More specifically, asgenerally illustrated in FIG. 4H, an angle between an exterior surfaceof the third segment 96C and the back surface 84 of the settling surfacecan be greater than 90°. In this manner, clarified liquid 42C can bedirected to a channel outlet 58 and does not have to flow downward toflow around the hollow support 90.

In one embodiment, the first segment 96A is oriented at an angle ofbetween approximately 120° and 130°, or approximately 125° with respectto the settling surface 62. Optionally, the first segment 96A and thesecond segment 96B are approximately perpendicular. Additionally, oralternatively, the second and third segments 96B, 96C can beapproximately perpendicular. In one embodiment, the first segment 96Aand the third segment 96C are approximately parallel. The fourth segment96D can be oriented at an angle of between approximately 50° and 60°, orapproximately 55° with respect to the third segment 96C. The fifthsegment 96E may be bent inwardly at an angle of between approximately40° and 50°, or approximately 45°, relative to the fourth segment 96D.

In one embodiment, the first segment 96A is interconnected to thesettling surface 62 by a first radius of curvature R1. Optionally, thefirst radius of curvature R1 can be between approximately 1/16 inchesand 5/16 inches, or approximately 3/16 inches. A second radius ofcurvature R2 can be formed between the first segment 96A and the secondsegment 96B. The second radius of curvature R2 can be betweenapproximately ⅛ inches and ⅝ inches, or approximately ⅜ inches. Further,an optional third radius of curvature R3 can be formed between thesecond segment 96B and the third segment 96C. In one embodiment, thethird radius of curvature R3 is between approximately 1/32 inches and5/32 inches, or approximately 1/16 inches.

The first segment 96A can have a length of between approximately 0.80inches and 1.10 inches. The second segment 96B is generally longer thanthe first segment. In one embodiment, the second segment 96B has alength of between approximately 1.30 inches and 1.70 inches. The thirdsegment 96C can have a length of between approximately 1.70 inches andapproximately 2.10 inches. Optionally, the fourth segment 96D has alength of from approximately 1.60 inches to 2.00 inches. Finally, theoptional fifth segment 96E may have a length of from approximately 0.10to 0.35 inches.

At least one of the first segment 96A, the second segment 96B, the thirdsegment 96C, the fourth segment 96D, and the fifth segment 96E can begenerally planar. Additionally, or alternatively, one or more of thesegments can have a shape that is not planar. For example, in oneembodiment, at least one of the segments 96A-96E is curved or arched.

Optionally, at least one of the segments 96 of the hollow support 90 canbe affixed or fastened to the settling surface. For example, in oneembodiment, the fourth segment 96D is affixed to the settling surface 62with a mechanical fastener 86. The mechanical fastener can be a rivet 86or the like. Alternatively, the mechanical fastener 86 can be a screw orbolt. Additionally, or alternatively, the fourth segment 96D can bejoined to the back surface 84 by any suitable means. In one embodiment,the fourth segment can be joined to the back surface 84 with one or moreof an adhesive, a glue, a weld, or a solder. In one embodiment, aprojection 142 (illustrated in FIG. 9 ) extending from a lateral side 72of the settling surface 62 can be bent around the fourth segment 96Dafter the hollow support 90 is formed to pinch or draw the fourthsegment against the back surface 84. In another embodiment, nomechanical fasteners penetrate the segments 96 of the hollow support 90.Accordingly, fewer operations are performed when forming the hollowsupport 90 which decreases the cost of the settler plate 60.

An orifice 98 is formed through the hollow support 90 to directclarified liquid into the hollow interior 92. The hollow support 90 caninclude any number of orifices 98. The size and number of orifices canbe selected to restrict the flow of clarified liquid 42C into the hollowsupport 90 to a predetermined rate according to the anticipated range offlow rates of the liquid 42 and the solids 40 into the basin 4. In thismanner, the desired flow rate of clarified liquid 42C through theorifices 98 is obtained. For example, flow rates of from about 1 GPM toabout 2 GPM into a hollow support through the orifices 98 of a platesettler 60 can be achieved.

In one embodiment, from four to eight orifices 98 are formed in thehollow support 90. The orifices 98 can be substantially evenly spacedacross the width 64 of the settling surface 62. By spacing the orifices98 across the settling surface width 64, the flow of liquid 42 can bemetered across the width of the settler plate 60 to facilitate even flowof the liquid as it rises up along the settling surface 62. In oneembodiment, at least one orifice 98M can be formed in a median portionof the width 64 of the hollow support as generally illustrated in FIGS.3A and 4D. Clarified liquid 42C flowing upward in a median portion of achannel 56 can then enter the hollow support 90 through the medianorifice 98M before flowing laterally toward one of the lateral sides 72of the settler plate 60. This can beneficially prevent a restriction inthe upward flow of the liquid 42 in the channel 56 and thus can promotea substantially uniform upward flow rate of the liquid across the width64 of the settler plate. Said differently, the clarified liquid 42C canbe evenly drawn into the hollow support 90 through orifices 98 acrossthe width 64 of the settling surface 62. In one embodiment, the liquid42 can flow less than approximately 7 inches laterally (or less thanabout ⅛th of the width 64) to reach an orifice 98 to flow into thehollow support 90.

In contrast, in some prior art settler plates, when a clarified liquidreaches an upper end of a channel, the liquid must flow laterally to anedge of the settler plate before more of the clarified liquid can flowto the channel upper end. More specifically, the clarified liquid mighthave to flow at least one-half of the width of the settler plate toreach a trough or weir of a prior art settler. The clarified liquid isdrawn off from the lateral edges of the settler plate. Liquid may poolor build up in the middle width of the channel, and the upward flow ofliquid in the middle of the channel may stagnate. This may cause arestriction in the upward flow of the liquid in some prior art settlerplates and create areas of decreased liquid flow, for example, in amiddle third of the settler plate.

The orifices 98 can be of any shape and dimension. In one embodiment,the orifices can be generally circular, oval, square, or elongatedslots. Optionally, each orifice 98 has a width or diameter of betweenapproximately 0.6 inches to approximately 0.8 inches. In one embodiment,the orifices 98 have a total surface area or cross-sectional area ofbetween approximately 1.2 square inches to approximately 2.7 squareinches. The orifices can be formed by punching or drilling through thehollow support.

The orifice 98 can be formed through the first segment 96A of the hollowsupport. Optionally, the orifice 98A can be formed through the optionalfourth segment 96D and the settling surface 62 of the settler plate 60.In one embodiment, the orifice 98B is formed through the second segment96B of the hollow support 90 and will generally face an adjacent settlerplate when the settler plate 60 is positioned in a clarifier 2.Additionally, or alternatively, an orifice 98C can be formed through thethird segment 96C of the hollow support.

In one embodiment, one or more of the orifices 98 can include a closureconfigured to selectively seal the orifice. In this manner, an operatorcan open or close one or more of the orifices 98 to adjust the flow ofclarified liquid 42C into a hollow support 90. The closure can beslidably associated with the settler plate 60. Additionally, oralternatively, the closure can be snapped or frictionally retained onthe settler plate. Optionally, the closure may comprise a plug that canbe selectively positioned within an orifice 98.

The settler plate 60 can include a flange or baffle 74 that extends fromone or both of the lateral sides 72 of the settling surface 62. In oneembodiment, the baffle 74 is integrally formed with the settlingsurface. For example, the baffle can be formed by bending a tab 132 thatextends from a lateral side of the settling surface 62 (as generallydescribed in conjunction with FIG. 9 ). The baffle 74 can beapproximately perpendicular to the settling surface. Optionally, thebaffle 74 extends away from the settling surface 62. In one embodiment,the baffle has a height of between approximately 0.5 inches andapproximately 2.0 inches.

A distal portion 76 of the baffle 74 is configured to contact a settlingsurface 62 of an adjacent settler plate as generally illustrated inFIGS. 4G-4H. In this manner, the height of the baffle 74 can define aheight of a channel 56 between the adjacent settler plates 60.

A flange 78 can extend from the distal portion 76 of the baffle. Theflange 78 (best seen in FIG. 4D) can be formed by folding or bending thebaffle distal portion 76. In one embodiment, the flange 78 issubstantially parallel to the settling surface 62. The flange 78A of afirst baffle 74A can extend toward the flange 78B of a second baffle74B. Accordingly, the flange 78 can extend under the settling surface 62of the settler plate 60. Optionally, the flange 78 has a width ofbetween approximately 0.3 inches and approximately 1.8 inches.

The flange 78 is configured to contact a settling surface 62 of anadjacent settler plate 60. In one embodiment, the flange 78 is adaptedto increase the strength or rigidity of the settler plate 60.Additionally, or alternatively, the flange 78 can distribute the forceapplied by a settler plate 60 to the settling surface of an adjacentsettler plate. Accordingly, the flange 78 can reduce damage orunintended bending to the adjacent settler plate. The flange 78 can alsohelp form a seal between adjacent settler plates 60. In this manner,liquid 42 may be prevented from unintentionally entering a channel 56between adjacent settler plates between a baffle 74 and a settlingsurface. Accordingly, the baffle 74 can be used in the clarifier toreplace one or more of the partitions 18. The flange 78 can thus improvethe efficiency of a settling plate 60.

Optionally, an interior angle between the flange 78 and the baffle 74can be at least 90°. For example, the interior angle can be betweenapproximately 91° and approximately 95°. In this manner, when the flangeis positioned against a settling surface 62 of an adjacent settler plate60, the flange 78 can create a biasing force and form the seal with theadjacent settling surface.

An end 80 of the baffle 74 proximate to the lower end 68 of the settlingsurface 62 can optionally be oriented at an angle with respect to thesettling surface 62 as generally shown in FIG. 4F. The angle can beselected such that when the settler plate 60 is positioned in a basin 4of a clarifier 2, the baffle end 80 will be substantially horizontal, asgenerally illustrated in FIG. 4G. Optionally, the baffle end 80 isapproximately parallel to a plane defined by the first segment 96A ofthe hollow support 90. The end 80 can be oriented at an angle of betweenapproximately 50° and 60°, or approximately 55° with respect to a backsurface 84 of the settler plate 60.

A port 82 can be formed through the baffle 74. The port has a size andgeometry selected to admit liquid 42 with solids 40 into a channel 56between adjacent settler plates 60 at a predetermined rate. The port 82is generally positioned closer to the lower end 68 than to the upper end66 of the settling surface 62. For example, a port 82 can be positionedat least approximately 1 inch from the lower end. In one embodiment,each baffle 74 has two or more ports 82.

The port 82 can have a generally rectangular shape such as illustratedin FIGS. 4C, 4F. Optionally, one or more corners of the port 82 can berounded or curved. Additionally, or alternatively, at least one port 82can be oval. In one embodiment, the settler plate 60 can include a port82 that has a round shape as generally illustrated in FIG. 4G. In oneembodiment, each baffle 74 can include up to six ports 82. The port 82can have a width or diameter of between approximately 0.25 inches andapproximately 1.5 inch. In another embodiment, the port can have alength of from approximately 1 inch to 9 inches.

The ports 82 can have different sizes. For example, in one embodiment afirst port 82A proximate to the baffle end 80 has a larger size than asecond port 82B positioned further from the baffle end 80. Eachsuccessive port 82 can decrease in size as the distance from the baffleend 80 increases. Forming a plurality of ports 82 with graduated sizescan enhance the flow characteristics of liquid 42 entering a channel 56.For example, the graduated ports 82 can reduce turbulence (or eddycurrents, changes in flow direction or velocity) in the flow of liquid42 within the channel 56 improving the rate at which solids 40 settleout of the liquid 42 and thereby increasing the efficiency of theclarifier 2.

The port 82 can be formed through the baffle 74 in a position so that,when the settler plate 60 is arranged in the clarifier 2 or plate pack50, as generally illustrated in FIG. 4G, liquid 42 containing the solid40 impurities (as an influent) is introduced into the channel 56 abovesolid particles 40 which have already separated from the liquid 42 andhave settled on (or are sliding down) the settling surface 62.Accordingly, in one embodiment, the port 82 is spaced a predetermineddistance from the distal portion 76 of the baffle 74. Optionally, theport 82 is at least approximately 0.2 inches from the baffle distalportion 76. In this manner, the port 82 is above a settling surface 62of an adjacent settler plate 60. Positioning the port 82 in this manneris beneficial because the liquid 42 with the solids 40 can be introducedinto the channel 56 in a manner which inhibits (and preferably,prevents) disrupting or disturbing solids 40 that have already separatedfrom liquid 42 in the channel. More specifically, by spacing the port 82from the baffle distal portion 76, turbulence or eddy currents at ornear a settling surface 62 of an adjacent settler plate 60 that resultsfrom the flow of liquid 42 through the port into a channel 56 can bereduced. Reducing turbulence near the settling surface 62 can increasethe speed at which the solids 40 settle out of the liquid 42, increasingthe efficiency of the settler plate of the present disclosure.

Referring now to FIG. 4F, a stiffening feature 70 can extend from thelower end 68 of the settling surface 62. In one embodiment, thestiffening feature 70 is integrally formed with the settling surface.For example, the stiffening feature 70 can be formed by bending orrolling a tab 126 (such as illustrated in FIG. 9 ) extending from thesettling surface 62. The stiffening feature 70 can be orientedapproximately perpendicular to the baffle end 80. In this manner, when asettler plate 60 is positioned in a plate pack 50 or clarifier 2, thestiffening feature can be oriented approximately vertically.

The stiffening feature 70 can be of any size and shape. Optionally, thestiffening feature 70 can have a cross-section that is generallyrectangular, such as generally illustrated in FIG. 4F. The stiffeningfeature 70A can be formed by bending a tab 126 of a blank 110 four ormore times. Alternatively, the stiffening feature may have across-section that is round, triangular, or square. In one embodiment,the stiffening feature 70 is generally flat. For example, the stiffeningfeature 70B can be formed by bending a first portion of the tab againsta second portion of the tab such as in the embodiment illustrated inFIG. 4G. Accordingly, the stiffening feature 70B illustrated in FIG. 4Gcan comprise two or more layers or thicknesses of a blank 110 from whichthe settler plate 60 is formed.

Referring now to FIG. 4H, the settler plates 60 can be spaced along thelongitudinal axis 20 of the basin 4. Each of the adjacent hollowsupports 90 is shown carrying one of the settler plates 60 such that thesettling surfaces 62 are substantially parallel. The settler plates 60can be arranged adjacent to each other and together define channels 56between the adjacent settler plates 60. The baffles 74 (illustrated inbroken lines for clarity) of the settler plates contact the settlingsurfaces 62 of adjacent settler places to form a wall. The wall causesthe liquid 42 to enter the channels 56 through the side ports 82.

As the solids 40 and the liquid 42 flow upwardly from the ports 82within the channels 56, the solids 40 settle from the liquid 42 onto thesettling surface 62. The solids 40 then slide down the settling surfaceto the bottom 14 of the basin 4 as generally indicated by arrow 47. Theclarified liquid 42C continues to flow upwardly to an outlet 58extending between a hollow support 90 of one settler plate and asettling surface 62 of an adjacent settler plate. Optionally, the outlet58 can have a width of between approximately 0.10 inches and 0.50inches, or between approximately 0.25 inches and approximately 0.375inches.

In one embodiment, in which the orifices 98 are formed in the firstsegment 96A, the clarified liquid 42C can flow above the first segment96A of the hollow support. The clarified liquid 42C can assume a level48A in the basin 4 above the first segment 96A of the hollow support 90.Accordingly, there may be some commingling of clarified liquid 42C fromone channel 56 with clarified liquid from another flow channel. Thelevel 48A of the liquid 42C can be controlled to be betweenapproximately 2 inches to approximately 6 inches above the top surfaceof the first segment 96A. Submerging the settler plates 60 and thehollow supports 90 in this manner can beneficially eliminate anair/water interface and thereby prevent or reduce corrosion of thesettler plates. Forming a volume of clarified liquid 42C above thehollow supports 90 can also create a pressure head above the settlerplates 60 and improve the flow of the clarified liquid into the hollowsupports. For example, the clarified liquid 42C flowing through theorifices 98 can create a substantially uniform headloss across the width64 of the settling surface 62. In one embodiment, the flow of clarifiedliquid 42C into the hollow supports 90 reduces the pressure head by upto approximately 0.5 inches.

Referring now to FIG. 4I, another embodiment of a hollow support 90 ofthe present disclosure is illustrated in which orifices 98A, 98B areformed through at least one of the settling surface 62 and the secondsegment 96B. Accordingly, the clarified liquid 42C can assume a level48B below the first segment 96A of the hollow support 90. Optionally,the level 48B of the clarified liquid 42C can be adjusted to be fromapproximately 0.125 inches to approximately 0.25 inches below the top ofthe first segment 96A. With the fluid level 48B in that range, theclarified liquid 42C between the adjacent settler plates 60 does notcompletely submerge the hollow supports 90. In this manner, theclarified liquid 42C does not flow over either or both of the hollowsupports 90. Rather, all of the clarified liquid 42C flows upwardly fromone of the channels 56, flows through the outlet 58 between a hollowsupport 90 and an adjacent settling surface 62, and flows into anopening or orifice 98A, 98B in one of the hollow supports 90.Optionally, the clarified liquid 42C can also flow through an optionalorifice 98C in the third segment 96C.

Because the fluid level 48B is lower than the top of the hollow support90, the clarified liquid 42C can directly and completely flow into andthrough the orifice 98A or 98B. Thus, in this embodiment, normally noneof the clarified liquid 42C from the outlet 58 of the channel 56 flowscompletely over either or both of the hollow supports 90, such thatthere is no commingling of clarified liquid 42C from the channel 56 withclarified liquid 42C from another one of the channels 56. Keeping thefluid level 48B lower than the top of the hollow support 90 alsobeneficially keeps the top deck of a plate pack 50 formed by the firstsegment 96A dry which may reduce or prevent growth of algae or otherbiological matter on the hollow supports 90.

Referring now to FIG. 5 , the flow of liquid in a channel 56 along asettling surface 62 of a settler plate 60 is generally illustrated. Nearthe upper end of the settler plate, clarified liquid 42C flows into ahollow support 90 associated with the settler plate. Once in the hollowinterior of the hollow support 90, the clarified liquid 42C flowslaterally toward an outlet trough 26 positioned proximate to one or bothlateral sides 72 of the settler plate 60. A baffle 34 can optionally beprovided at lateral sides of the settler plate 60. The baffle 34 canextend upwardly above the hollow support 90 of the settler plate. Inthis manner, a head of clarified liquid 42C can collect above the hollowsupport.

Optionally, a weir 30 is provided with the troughs 26. The clarifiedliquid 42C can flow over the weir 30 into the trough 26. Optionally, theweir 30 can be adjusted to alter the level 48 of the clarified liquid42C. For example, the position of the weir can be adjusted higher orlower relative to the trough 26 to allow the level 48 of the clarifiedliquid 42C to be set according to the particular level 48 that isdesired (such as generally illustrated in FIGS. 4H and 4I).

Clarified liquid 42C from a channel 56 can be sampled to determine ifthe settler plates 60 need servicing or replacement. In one embodiment,if it is found by such sampling that too many solids 40 are present inthe clarified liquid 42C from a channel 56, then one or both of thesettler plates 60 and the associated hollow supports 90 that define thatflow channel 56 can be removed for cleaning or replacement. Optionally,the settler plates 60 can be releasably retained by the clarifier 2. Inthis manner, the servicing operations of removal and replacement of oneor both such fouled settler plates 60 can be performed withoutinterrupting or substantially impairing the normal settling operationsof the other flow channels 56. For example, after removing a settlerplate 60, a plug (not illustrated) can be placed in a trough inlet 32formed through a baffle 34 associated with the weir 30. In this manner,flow of clarified fluid through the trough inlet 32 (illustrated in FIG.6 ) can be blocked.

In one embodiment, to facilitate removal of a fouled settler plate 60and the corresponding hollow support 90, FIG. 6 depicts an embodiment ofthe trough 26 in which the respective hollow supports 90 are removablefrom the trough 26. The upper end of the trough 26, which may be theweir 30 for example, includes an upper mounting plate or baffle 34. Thebaffle 34 can optionally be configured to be removably interconnected tothe trough 26 or a portion of the weir 30. A lower surface of the baffle34 is shaped to define a series of recesses 36. Each recess 36 isadapted to fit over, or receive, one of the hollow supports 90 and tospace such hollow support 90 from an adjacent hollow support 90according to the desired width of the channels 56. The recesses 36 canhave a shape adapted to substantially conform to the shape of theexternal surface of all hollow supports 90 of present disclosure. Inthis manner, a seal can be formed by the trough 26 and baffle 34 with anexterior surface of the hollow support 90. After the baffle 34 is placedover the hollow supports 90, the baffle 34 can be fastened to secure thehollow supports 90 to the trough 26. Optionally, depending on thecross-sectional shape of the hollow supports 90, an upper surface of thetrough 26 can include projections, recesses or depressions (notillustrated) to conform to a portion of the external surface of thehollow supports.

In one embodiment, to remove any of the hollow supports 90 of theclarifier 2, the baffle 34 can be removed from the trough 26. Thedesired hollow support 90 can then be removed exposing a trough inlet 32formerly connected to the now-removed hollow support 90. This isgenerally illustrated in FIG. 6 in which a hollow support has beenremoved to leave a vacant inlet 32 in between two adjacent hollowsupports 90. Once the desired hollow support 90 is removed, a plug (notillustrated) with a shape corresponding to the inlet 32 can be insertedto block the inlet. Alternatively, the settler plates 60 can be fixedlyjoined to the baffle 34. In one embodiment, the hollow supports 90 canbe welded to the inlets 32 of the baffle 34.

Referring now to FIGS. 7-8 , settler plates 60 according to otherembodiments of the present disclosure are illustrated. Morespecifically, FIG. 7 illustrates a portion of a settler plate 60 thatincludes a hollow support 90A that has a generally cylindrical shape.The hollow support 90A can be integrally formed with the settlingsurface 62. For example, the cylindrical hollow support 90A can beformed by rolling a tab that extends from the upper end 66 of thesettling surface 62. Alternatively, the cylindrical hollow support 90Acan be formed by folding or bending the tab a plurality of times.Regardless, a free end 99 of a tab 114 (such as illustrated in FIG. 9 )used to form the hollow support 90A extends proximate to a back surface84 of the settling surface. The free end 99 can extend within the hollowinterior 92 of the hollow support 90A.

FIG. 8 illustrates a portion of another settler plate 60 that includes ahollow support 90B with a cross section that is generally triangular.The triangular hollow support 90B can be integrally formed with thesettling surface 62 by bending a tab 114 that extends from the settlingsurface 62 into a desired shape. In one embodiment, the triangularhollow support 90B is formed by bending the tab 114 at least two times.A free end 99 of the tab can extend within a hollow interior 92 of thehollow support 90B

Although not illustrated, the settler plates 60 illustrated in FIGS. 7-8, can include orifices 98 and or a mechanical fastener 86 that are thesame as, or similar to, the orifices and optional mechanical fastener 86of the settler plate 60 described in conjunction with FIGS. 4A-4I. Forexample, one or more orifices 98 can be formed in a variety of locationsof the cylindrical hollow support 90A. Similarly, an orifice 98 can beformed through one or more of the three sides of the triangular support42B.

Referring now to FIG. 9 , a blank 110 of an embodiment of the presentdisclosure is generally illustrated. The blank 110 can be formed into asettler plate 60 of embodiments of the present disclosure. In oneembodiment, the blank 110 is formed of a 20 to 26 gauge material, or a24 gauge material. The material of the blank 110 can be a stainlesssteel alloy, such as a 304 stainless steel alloy. Alternatively, theblank can be formed of carbon steel, aluminum, or bendable plastic, suchas Acrylonitrile butadiene styrene (ABS). The blank 110 can have alength of between approximately 90 inches and approximately 140 inches.A width of the blank can be between approximately 40 inches andapproximately 80 inches. The blank 110 is generally planar.

The blank 110 generally includes a central sheet 112, a first end tab114, a second end tab 126 and two lateral tabs 132A, 132B. The centralsheet 112 can form a settling surface 62 of a settler plate 60. Notches138 can be formed between the first end tab 114 and the lateral tabs132. Similarly, mitered notches 140 can be formed between the second endtab 126 and the lateral tabs. The notches 138, 140 can be provided tofacilitate bending of the tabs 114, 126, 132 into predetermined shapes.Ports 82 for effluent can optionally be formed in the blank 110.Although the ports 82 are illustrated with a rectangular shape, theports can have a circular shape.

A plurality dashed lines are shown. Each dashed line represents an axisof bending, or bend axis, for a location at which the blank can be bentor folded to form the settler plate 60.

The first end tab 114 generally includes one or more bend axes 116, 118,120, 122, and optionally 124. The bend axes indicate locations at whichthe first end tab 114 can be bent to form a hollow support, such asgenerally illustrated in FIG. 4E. More specifically, the axes 116-124generally define the first through fifth segments 96A—96E of the hollowsupport. Optionally, one or more orifices 98 can be formed in the firstend tab 114. In one embodiment, at least one orifice 98 is formedbetween the first bend axis 116 and the second bend axis 118.

Referring now to FIGS. 10A-10F, the hollow support 90 can be formed bybending the first end tab 114 proximate to the bend axes 116-124. Anybending or folding apparatus can be used. One example of a suitablefolding machine that can be used to form a blank 110 into a settlerplate 60 is an RAS XLTbend. Other suitable folding machines are known tothose of skill in the art.

Referring now to FIG. 10A, in one embodiment, the hollow support of thepresent disclosure is formed by bending an outer portion of the firstend tab 114 around the fifth axis 124 to define the fifth segment 96E.The first end tab 114 can be bent or folded at an angle of approximately135° at the fifth axis 124. The first end tab 114 can also be bent orfolded at the fourth axis 122 to define the fourth segment 96D as shownin FIG. 10B. Optionally, the first end tab 114 is bent or folded at anangle of approximately 125° at the fourth axis 122. Similarly, the firstend tab 114 can be bent or folded at the third axis 120, the second axis118, and the first axis 116 to form the third segment 96C, secondsegment 96B, and the first segment 96A. The first end tab 114 can bebent by approximately 90° at the third axis 120, approximately 90° atthe second axis 118, and approximately 55° at the first axis 116.

The bending or folding at the bend axes 116-124 can be performed in oneor more operations. More specifically, in one embodiment generallyillustrated in FIG. 10D, the first end tab 114 can be bent a first timeat the second axis 118. Referring to FIG. 10E, the first end tab 114 canthen be bent by approximately 55° at the first axis 116. The first endtab 114 can then be bent a second time at the second axis 118 as shownin FIG. 10F. In this manner, the hollow support 90 can be formed withoutthe material of the first end tab 114 interfering with operation of abend or folding apparatus used to perform the bending or folding. In oneembodiment, the tab is bent by approximately 45° during the first bendat the second axis 118. The second bend at the second axis 118 can alsobe by approximately 45°.

Returning to FIG. 9 , the second end tab 126 can be formed into astiffening feature 70 of embodiments of the present disclosure. In oneembodiment, the second end tab 126 can be bent or folded approximatelyin half at the seventh axis 130, or by approximately 180°. Optionally,the second end tab 126 can be folded in half one or more additionaltimes. The second end tab 126 can next be bent or folded byapproximately 35° at the sixth axis 128. In this manner, the stiffeningfeature 70B of the embodiment illustrated in FIG. 4G can be formed.

Alternatively, the second end tab 126 can be bent to form the stiffeningfeature 70 as generally illustrated in FIG. 4F. In one embodiment, thesecond end tab 126 is bent at least four times to form the stiffeningfeature 70A.

The lateral tabs 132 can be bent one or more times to form baffles 74 ofembodiments of the present disclosure. More specifically, the lateraltabs 132 can be bent or folded by approximately 90° at the eighth axis134 to define the baffles 74 of the present disclosure. In oneembodiment, the lateral tabs 132 are bent or folded by approximately 90°at the ninth axis 136 to form flanges 78.

Referring now to FIGS. 11-16 , a settler plate 60 of another embodimentof the present disclosure is generally illustrated. The settler plate 60includes many of the same, or similar, features as the embodiments ofthe settler plates 60 described in conjunction with FIGS. 2-10 . Thesettler plate 60 operates in a similar manner as the settler plates ofother embodiments described herein and provides similar benefits andadvantages.

Referring now to FIGS. 11-12 , a plate pack 50 of another embodiment ofthe present disclosure is generally illustrated. The plate pack 50comprises a plurality of settler plates 60 supported by a frame 51. Inone embodiment, the plate pack 50 includes from approximately eight toapproximately one hundred forty settler plates. Optionally, a cover(such as the cover 52 illustrated in FIG. 2 ) can be used with the platepack 50. The plate pack 50 can be installed in a basin 4 with, or inplace of, a clarifier section 16 such as described in conjunction withFIG. 1 .

The plate pack 50 is adapted to retain the settler plates in apredetermined orientation. More specifically, the frame 51 holds thesettler plates 60 at a predetermined angle 1 relative to a horizontalaxis 20. In one embodiment, the angle 1 is between approximately 45° andapproximately 65°. In another embodiment, the angle is approximately55°. Each settler plate 60 is approximately parallel to an adjacentsettler plate.

Referring now to FIGS. 13-14 , portions of the plate pack 50 and settlerplates 60 of an embodiment of the present disclosure are generallyillustrated. Each settler plate 60 includes a hollow support 90. Thehollow supports 90 are configured to carry one settler plate 60 in theframe 51. In one embodiment, a portion of the hollow support 90 extendsover a horizontal portion of the frame 51H of the plate pack 50 asgenerally illustrated.

The hollow support can be fastened or affixed to the settler plate. Morespecifically, the hollow support can be affixed to the settler plate bya weld, a rivet, a bolt, a screw, a mechanic al interlocking attachment,an adhesive, and other known attachment means. In one embodiment, amechanical fastener 86 can extend through a portion of the settler plateinto the hollow support 90. Additionally, or alternatively, in oneembodiment a hollow support 90 can be integrally formed at an upper endof a settler plate 60.

Adjacent hollow supports 90 carry respective adjacent settler plates 60in a predetermined alignment to define one channel 56. In oneembodiment, a distance 95 between hollow supports 90 of adjacent settlerplates is between approximately 2.0 inches and 2.5 inches, orapproximately 2.25 inches.

Opposite ends of each hollow support 90 are engaged with the frame anddirect clarified liquid from a channel between the settler plates to atrough (such as illustrated in FIG. 1 ). Although not illustrated inFIGS. 13-14 for clarity, a trough and/or a weir can be positionedproximate to a vertical portion 51V of the frame in a manner similar tothat shown in FIG. 5 . In one embodiment, a trough and a weir areinterconnected to the horizontal portion 51H of the frame 51.Optionally, the trough and weir may be interconnected to a projection,such as a pin or stud 54, of the horizontal portion 51H.

The engagement of the hollow support to the frame can be removable asdescribed herein. Alternatively, the hollow supports 90 can be fixed tothe plate pack 50. Specifically, the hollow support 90 can be joined toa portion of the frame 51, such as a support element or baffle 34 (knownas a comb) by a fastener, a mechanical interlocking attachment, a weld,or other means.

Referring now to FIGS. 15A-15G, settler plates 60 of an embodiment ofthe present disclosure are generally illustrated. A settler plate 60includes a settling surface 62 with an upper end 66, a lower end 68, andlateral sides 72. The settling surface 62 can have a shape that isgenerally rectangular and substantially planar.

In one embodiment, the settling surface 62 has a length of betweenapproximately 100 inches and approximately 130 inches, or approximately114 inches. Optionally, the settling surface has a width 64 of betweenapproximately 44 inches and approximately 64 inches, or approximately 54inches. The settling surface 62 is generally smooth to facilitatemovement of solids 40 that collect on the settling surface 62 toward thelower end 68. Optionally, a coating can be added to the settling surface62 to prevent, or reduce the likelihood, of solids sticking. In oneembodiment, the coating can be a polytetrafluoroethylene (PTFE) (such asTeflon), a silicone, an enamel, or a ceramic. In one embodiment, thesettling surface is polished.

The settler plate 60 can be made of any suitable material, such as oneor more of stainless steel, fiber reinforced composites, plastic,polyvinyl chloride (PVC), carbon steel, and aluminum. In one embodiment,the settler plate 60 comprises a 304 stainless steel alloy. The materialfrom which the settler plate 60 is formed can have a thickness ofbetween approximately 0.015 inches and 0.035 inches. Optionally, thesettler plate 60 is formed of a 20 to 26 gauge material. In oneembodiment, the settle plate is manufactured from a 24 gauge stainlesssteel alloy.

A hollow support 90 extends from the settler plate 60 proximate to theupper end 66. The hollow support 90 includes a hollow interior 92. Inone embodiment, the hollow support 90 projects or extends away from thesettling surface 62. For example, the hollow interior 92 can bepositioned to extend above the settling surface 62 of the settler plate.More specifically, the hollow support 90 can be formed such that a planecontacting the back surface 84 is not interrupted by the hollow support.Said differently, the hollow support can be oriented such that noportion of the hollow support 90 contacts the plane contacting the backsurface.

A width 94 of the hollow support can be greater than the width 64 of thesettling surface. For example, the width 94 of the hollow support 90 canbe between approximately 46 inches and approximately 66 inches, orapproximately 56 inches. Accordingly, at least a portion of the hollowsupport 90 can extend beyond one or both baffles 74 positioned at thelateral sides 72 of the settling surface 62 as generally illustrated inFIG. 15D. In one embodiment, the width 94 of the hollow support 90 is atleast approximately 3% greater than the width 64 of the settlingsurface.

In one embodiment, the hollow support 90 is integrally formed with thesettling surface 62. For example, the hollow support 90 can be formed byaltering the shape of a tab 114 extending from the upper end 66 asgenerally described in conjunction with FIG. 16 .

The hollow support 90 is illustrated in FIG. 15E with four exteriorsides. Optionally, the hollow support 90 can have a cross-section of atrapezoid. However, the hollow support 90 can have other configurationswith more, or fewer sides. In one embodiment, the hollow support 90 hasa cross-sectional shape of a regular or irregular polygon.

Referring now to FIG. 15E, in one embodiment the hollow support 90includes a number of segments 96 formed by bending or folding the tabextending from the settling surface 62. For example, the hollow support90 can comprise a first segment 96A interconnected to the settlingsurface 62. An interior angle between the first segment 96A and thesettling surface 62 may be between approximately 140° and approximately150°, or approximately 145°.

A second segment 96B can extend from the first segment. In oneembodiment, the second segment is approximately perpendicular to thefirst segment.

A third segment 96C of the hollow support 90 can extend from the secondsegment 96B. In one embodiment, and interior angle between the secondsegment and the third segment is between approximately 116° andapproximately 120°, or approximately 118°.

A fourth segment 96D can run from the third segment 96C. An interiorangle between the third and fourth segments may be between approximately60° and approximately 64°, or approximately 62°. Accordingly, the fourthsegment 96D may optionally be oriented approximately parallel to thesecond segment 96B.

Additionally, a fifth segment 96E can extend inwardly from an end of thefourth segment 96D. In one embodiment, the fifth segment isapproximately perpendicular to the fourth segment. The fifth segment 96Ecan extend approximately parallel to the first segment 96A. Optionally,at least a portion of the fifth segment can contact the first segment.

In one embodiment, when the settler plate 60 is positioned in a platepack 50, one or more of the second segment 96B and the fourth segment96D can be approximately horizontal, or parallel to longitudinal axis20, as generally illustrated in FIG. 14 . Additionally, oralternatively, the first and fifth segments 96A, 96E may beapproximately perpendicular to the longitudinal axis 20.

Optionally, a sixth segment 96F may extend from the fifth segment. Inone embodiment, an interior angle between the fifth and sixth segmentsis between approximately 25° and approximately 65°. The sixth segment96F is configured to increase the stiffness of one or more of thesegments 96 and of the hollow support 90. For example, the sixth segment96F can increase the stiffness of the hollow support 90 such that thesettling surface 62 and the other segment 96A-96E do not bend or deformif a mechanical fastener 86 is added to the hollow support. Accordingly,in one embodiment, because of the sixth segment 96F, the hollow support90 can be formed of less (or thinner) material without decreasing thestrength of the hollow support, beneficially reducing the materialexpense of the settler plate 60.

Each segment is joined to one or more adjacent segments or the settlingsurface by a predetermined radius of curvature. In one embodiment, eachradius of curvature is between approximately 1/32 of an inch andapproximately 3/32 of an inch, or approximately 1/16 of an inch.

The first segment 96A can have a length of between approximately 1.40inches and 1.60 inches. The second segment 96B is generally shorter thanthe first segment. In one embodiment, the second segment 96B has alength of between approximately 0.90 inches and 1.10 inches. The thirdsegment 96C can have a length of between approximately 1.40 inches andapproximately 1.6 inches. Optionally, the fourth segment 96D has alength of from approximately 1.60 inches to 1.90 inches. The fifthsegment 96E may have a length of from approximately 1.3 to 1.5 inches.The sixth segment 96F can optionally have a length of about 0.25 inches.

At least one of the first-sixth segments is generally planar.Additionally, or alternatively, one or more of the segments can have ashape that is not planar. For example, in one embodiment, at least oneof the segments 96A—96F is curved or arched.

Optionally, at least one of the segments 96 of the hollow support 90 canbe affixed or fastened to another segment. For example, in oneembodiment, the first segment 96A is attached to the fifth segment 96Ewith a mechanical fastener 86. The mechanical fastener can be a rivet 86or the like. Alternatively, the mechanical fastener 86 can be a screw orbolt. Optionally, five fasteners 86 are positioned through the first andfifth segments.

Additionally, or alternatively, the fifth segment 96E can be joined tothe first segment 96A by any other suitable means. In one embodiment,the fifth segment is joined to the first segment with one or more of anadhesive, a glue, a weld, or a solder. In one embodiment, a projection142 (illustrated in FIG. 16 ) extending from a lateral side 72 of ametal blank 110 from which the settler plate is formed can be bentaround the fifth segment 96E after the hollow support 90 is formed topinch or draw the fifth segment against the first segment.

In another embodiment, no mechanical fasteners penetrate the segments 96of the hollow support 90. Accordingly, fewer operations are performedwhen forming the hollow support 90 which decreases the cost of thesettler plate 60.

An orifice 98 is formed through the hollow support 90 to directclarified liquid into the hollow interior 92. The hollow support 90 caninclude any number of orifices 98. The size and number of orifices canbe selected to restrict the flow of clarified liquid 42C into the hollowsupport 90 to a predetermined rate according to the anticipated range offlow rates of the liquid 42 and the solids 40 into the basin 4. In thismanner, the desired flow rate of clarified liquid 42C through theorifices 98 is obtained. For example, flow rates of from about 1 GPM toabout 2 GPM into a hollow support 90 through the orifices 98 of a platesettler 60 can be achieved.

In one embodiment, from four to ten orifices 98 are formed in the hollowsupport 90. Optionally, the hollow support 90 can have five orifices 98.The orifices 98 can be substantially evenly spaced across the width 64of the settling surface 62. By spacing the orifices 98 across thesettling surface width 64, the flow of liquid 42 can be metered acrossthe width of the settler plate 60 to facilitate even flow of the liquidas it rises up along the settling surface 62. The even flow of clarifiedliquid through the orifices 98 into the hollow support 90 establishes aconstant upward flow and even distribution across the width of thesettling surface 62. The constant upward flow of liquid through thechannels 56 between adjacent settler plates 60 eliminates dead zones onthe settling surfaces 62 and ensures full utilization of the surfacearea of the settling surfaces.

The orifices also create a headloss which is required for even flow andsmooth operation of the clarifier 2. Further, the orifices create anequalized distribution of clarified liquid across the entire surface ofthe plate pack 50.

In contrast, some prior art settler plates allow liquid to collect abovethe tops of the plates. This can restrict the flow of liquid and createareas of uneven flow along the settler plates, reducing the efficiencyof the settler plates.

In one embodiment, at least one orifice 98M can be formed in a medianportion of the width 64 of the hollow support 90 as generallyillustrated in FIG. 15D. The median orifice 98M can be (but is notnecessarily) substantially centered on the width 94 of the hollowsupport. Clarified liquid 42C flowing upward in a median portion of achannel 56 can then enter the hollow support 90 through the medianorifice 98M before flowing laterally toward one of the lateral sides 72of the settler plate 60. This can beneficially prevent a restriction inthe upward flow of the liquid 42 in the channel 56 and thus can promotea substantially uniform upward flow rate of the liquid across the width64 of the settler plate. Said differently, the clarified liquid 42C canbe evenly drawn into the hollow support 90 through orifices 98 acrossthe width 64 of the settling surface 62. In one embodiment, the liquid42 can flow less than approximately 7 inches laterally (or less thanabout ⅛th of the width 64) to reach an orifice 98 to flow into thehollow support 90.

The orifices 98 can be of any shape and dimension. In one embodiment,the orifices can be generally circular, oval, square, or elongatedslots. Optionally, each orifice 98 has a width or diameter of betweenapproximately 0.5 inches to approximately 0.8 inches. In one embodiment,the orifices 98 have a total surface area or cross-sectional area ofbetween approximately 1.2 square inches to approximately 2.7 squareinches. The orifices can be formed by punching or drilling through thehollow support.

The orifice 98 can be formed through any one or more segments 96 of thehollow support. In one embodiment, the orifice 98 is formed through thesecond segment 96B as generally illustrated in FIG. 15E. Accordingly,the orifice 98 will generally face upwardly when the settler plate 60 ispositioned in a clarifier 2. Additionally, or alternatively, an orifice98 can be formed through the first and fifth segments 96A, 96E oroptionally the third segment 96C of the hollow support.

In one embodiment, one or more of the orifices 98 can include a closureconfigured to selectively seal the orifice. In this manner, an operatorcan open or close one or more of the orifices 98 to adjust the flow ofclarified liquid 42C into a hollow support 90. The closure can beslidably associated with the settler plate 60. Additionally, oralternatively, the closure can be snapped or frictionally retained onthe settler plate. Optionally, the closure may comprise a plug that canbe selectively positioned within an orifice 98.

The settler plate 60 can include a flange or baffle 74 that extends fromone or both of the lateral sides 72 of the settling surface 62. In oneembodiment, the baffle 74 is integrally formed with the settlingsurface. For example, the baffle can be formed by bending a tab 132 thatextends from a lateral side of the settling surface 62 (as generallydescribed in conjunction with FIG. 16 ). The baffle 74 can beapproximately perpendicular to the settling surface 62. Optionally, thebaffle 74 extends upwardly above the settling surface 62. In oneembodiment, the baffle has a height of between approximately 0.5 inchesand approximately 2.0 inches. In one embodiment, the baffle height isapproximately 1.8 inches.

A distal portion 76 of the baffle 74 is configured to contact a backsurface 84 of an adjacent settler plate as generally illustrated in FIG.15G. In this manner, the height of the baffle 74 can define a height ofa channel 56 between the adjacent settler plates 60.

A flange 78 can extend from the distal portion 76 of the baffle. Theflange 78 (best seen in FIG. 15D) can be formed by folding or bendingthe baffle distal portion 76. In one embodiment, the flange 78 issubstantially parallel to the settling surface 62. The flange 78A of afirst baffle 74A can extend toward the flange 78B of a second baffle74B. Accordingly, the flange 78 can extend inwardly above the settlingsurface 62 of the settler plate 60. Optionally, the flange 78 has awidth of between approximately 0.3 inches and approximately 1.8 inches.

The flange 78 is configured to contact a back surface 84 of an adjacentsettler plate 60. In one embodiment, the flange 78 is adapted toincrease the strength or rigidity of the settler plate 60. Additionally,or alternatively, the flange 78 can distribute the force applied by asettler plate 60 to the back surface of an adjacent settler plate.Accordingly, the flange 78 can reduce damage or unintended bending tothe adjacent settler plate. The flange 78 can also help form a sealbetween adjacent settler plates 60. In this manner, liquid 42 may beprevented from unintentionally entering a channel 56 between adjacentsettler plates between a baffle 74 and a back surface 84. Accordingly,the baffle 74 can be used in the clarifier to replace one or more of thepartitions 18. The flange 78 can thus improve the efficiency of asettling plate 60.

Optionally, an interior angle between the flange 78 and the baffle 74can be at least 90°. For example, the interior angle can be betweenapproximately 91° and approximately 95°. In this manner, when the flangeis positioned against a settling back 84 of an adjacent settler plate60, the flange 78 can create a biasing force and form the seal with theadjacent settling surface.

A lower end 80A of the baffle 74 proximate to the lower end 68 of thesettling surface 62 may be approximately perpendicular to the settlingsurface 62 as generally illustrated in FIG. 15F. Optionally, an upperend 80B of the baffle 74 may be angled relative to the settling surfaceas shown in FIG. 15E. In one embodiment, an interior angle between theupper end 80B and the settling surface 62 is between approximately 50°and 60°, or approximately 55°. In one embodiment, the upper end 80B isapproximately parallel to the fourth segment 96D. Additionally, oralternatively, the upper end 80B can contact the fourth segment 96D. Inthis manner, the upper end 80B and the fourth segment can define a sealto prevent or limit the flow of liquid between the fourth segment 96Dand the baffle 74.

A port 82 can be formed through the baffle 74. The port has a size andgeometry selected to admit liquid 42 with solids 40 into a channel 56between adjacent settler plates 60 at a predetermined rate. In oneembodiment, each baffle 74 has two or more ports 82.

The port 82 is generally positioned closer to the lower end 80A than tothe upper end 80B of the baffle. For example, a port 82 can bepositioned at least approximately 1 inch from the lower end 80A. Placingthe port 82 closer to the lower end 80A is beneficial because floatingdebris, such as leaves, plastic, oil, grease, and similar debris willgenerally be at a level in the detention basin that is higher than theports 82. Accordingly, floating debris is unlikely to pass through theports 82 and enter the channel 56 between the settler plates 60.

The port 82 may have any shape. Optionally, the port 82 is square orrectangular as described in conjunction with FIG. 4F. In one embodiment,each baffle 74 has at two or more rectangular ports 82 as shown in FIG.4C. Additionally, or alternatively, in one embodiment, the port 82 ofthe settler plate 60 has a round shape or circular as generallyillustrated in FIG. 15F. In one embodiment, each baffle 74 can includeup to eight ports 82. Optionally, each baffle has six ports 82.

The port 82 can have a width or diameter of between approximately 0.25inches and approximately 2 inches. Optionally, the port 82 has adiameter of approximately 1.5 inches. A lower or first port 82 can becentered between approximately 2.4 inches and 2.5 inches from the lowerend 80A of the baffle 72. In this manner, liquid 42 with solids 40 canenter the channel 56 between adjacent settler plates a predetermineddistance from the lower end 68 of the settler place to avoid drawingsettled solids 40 back into a channel or disturbing the downwardmovement of the solids. Additional ports 82 may be centered about 2.5inches upwardly from a lower or first port 82A.

The ports 82 can have different sizes. For example, in one embodimentthe first port 82A proximate to the lower end 80A has a larger size thana second port 82 positioned further from the baffle end 80A. In oneembodiment, each successive port 82 can decrease in size as the distancefrom the lower end 80A increases. Forming a plurality of ports 82 withgraduated sizes can enhance the flow characteristics of liquid 42entering a channel 56. For example, the graduated ports 82 can reduceturbulence (or eddy currents, changes in flow direction or velocity) inthe flow of liquid 42 within the channel 56 improving the rate at whichsolids 40 settle out of the liquid 42 and thereby increasing theefficiency of the clarifier 2.

The port 82 can be formed through the baffle 74 in a position so that,when the settler plate 60 is arranged in the clarifier 2 or plate pack50, liquid 42 containing the solid 40 impurities (as an influent) isintroduced into the channel 56 above solid particles 40 which havealready separated from the liquid 42 and have settled on (or are slidingdown) the settling surface 62. Accordingly, in one embodiment, the port82 is spaced a predetermined distance 83 above the settling surface 62on the baffle 74. Optionally, the distance 83 between the port 82 andthe settling surface 62 is at least approximately 0.1 inches, orapproximately 0.19 inches. Positioning the port 82 in this manner isbeneficial because the liquid 42 with the solids 40 can be introducedinto the channel 56 in a manner which inhibits (and preferably,prevents) disrupting or disturbing solids 40 that have already separatedfrom liquid 42 in the channel. More specifically, by spacing the port 82from the settling surface, turbulence or eddy currents at or near asettling surface 62 of the settler plate 60 that results from the flowof liquid 42 through the port into a channel 56 can be reduced. Reducingturbulence near the settling surface 62 can increase the speed at whichthe solids 40 settle out of the liquid 42, increasing the efficiency ofthe settler plate of the present disclosure.

Referring now to FIG. 15F, a stiffening feature 70 can optionally extendfrom the lower end 68 of the settling surface 62. The stiffening featurehelps prevent or reduce bending or warping of the settling surface.

In one embodiment, the stiffening feature 70 is integrally formed withthe settling surface. For example, the stiffening feature 70 can beformed by bending or rolling a tab 126 (such as illustrated in FIG. 16 )extending from the settling surface 62. The stiffening feature 70 can beoriented at a predetermined angle below the settling surface.Optionally, the stiffening feature extends below the settling surface atan angle of between approximately 40° and approximately 50°, orapproximately 44°. In this manner, when a settler plate 60 is positionedin a plate pack 50 or clarifier 2, the stiffening feature can beoriented approximately vertically.

The stiffening feature 70 can be of any size and shape. The stiffeningfeature 70 can be formed by bending a tab 126 of a blank 110 two or moretimes. In one embodiment, the stiffening feature 70 is generally flat.For example, the stiffening feature 70 can be formed by bending a firstportion of the tab against a second portion of the tab such as in theembodiment illustrated in FIG. 15F. Accordingly, the stiffening feature70 illustrated in FIG. 15F can comprise two or more layers orthicknesses of a blank 110 from which the settler plate 60 is formed.

Referring now to FIG. 15G, the settler plates 60 can be spaced along thelongitudinal axis of the basin 4. Each of the adjacent hollow supports90 is shown carrying one of the settler plates 60 such that the settlingsurfaces 62 are substantially parallel. The settler plates 60 can bearranged adjacent to each other and together define channels 56 betweenthe adjacent settler plates 60. The baffles 74 (illustrated in brokenlines for clarity) of the settler plates contact the back surfaces 84 ofadjacent settler places to form a wall. The wall formed by the bafflescauses the liquid 42 to enter the channels 56 through the side ports 82.More specifically, the baffles prevent liquid 42 from unintentionallyflowing laterally into the channels and causes influent to enter thechannels through the side ports 82. Introducing the influent flow acrossthe settler plates 60 from the lateral sides through the port 82 allowsthe down-flowing sludge and solids 40 to fall below the channels 56 intoa quiet zone in the detention basin 2 beneath the settler plates 60. Forexample, as shown in FIG. 1 , the lower ends 68 of the settler platesare spaced from the bottom 14 of the basin. The area between the platelower ends 68 and the basin bottom 14 forms a “quiet zone” with littlemovement or turbulence in the liquid. By limiting the introduction ofliquid 42 into the channels 56 through the side ports 82, the settlerplates 60 of all embodiments of the present disclosure ensure minimuminterference with the downward movement of solids 40 to the basin bottom14 where the solids can be collected.

In contrast, some prior art settler plates are designed to introduceliquid into a channel between adjacent settler plates from the bottom,which can interfere with the downward movement of solids. The liquidflowing into the channels from the bottom of the settler plates maycause solids to move upwardly in the basin rather than downwardly asintended.

As the solids 40 and the liquid 42 flow upwardly from the ports 82within the channels 56 (as generally illustrated in FIGS. 4G and 5 ),the solids 40 settle from the liquid 42 onto the settling surface 62.The solids 40 then slide down the settling surface to the bottom 14 ofthe basin 4 as generally indicated by arrows 47. The clarified liquid42C continues to flow upwardly to an outlet 58 extending between ahollow support 90 of one settler plate and a hollow support of anadjacent settler plate. Optionally, the outlet 58 can have a width ofbetween approximately 0.10 inches and 0.50 inches, or betweenapproximately 0.25 inches and approximately 0.375 inches.

In one embodiment, in which the orifices 98 are formed in the secondsegment 96B, the clarified liquid 42C can flow above the second segment96B of the hollow support. The clarified liquid 42C can assume a level48A in the basin 4 above the second segment 96B of the hollow support90. Accordingly, there may be some commingling of clarified liquid 42Cfrom one channel 56 with clarified liquid from another flow channel.

The level 48A of the clarified liquid 42C can be controlled by adjustingthe position of a weir 30 (such as described in conjunction with FIG. 5) upwardly or downwardly. By changing the position of the weir, thelevel 48A of clarified liquid 42C can be adjusted to be betweenapproximately 0.25 inches to at least approximately 6 inches above thetop surface of the second segment 96B. Submerging the settler plates 60and the hollow supports 90 in this manner can beneficially eliminate anair/water interface and thereby prevent or reduce corrosion of thesettler plates. Forming a volume of clarified liquid 42C above thehollow supports 90 can also create a pressure head above the settlerplates 60 and improves the flow of the clarified liquid into the hollowsupports. For example, the clarified liquid 42C flowing through theorifices 98 can create a substantially uniform headloss across the width64 of the settling surface 62. The substantially uniform headloss inturn provides an even flow of liquid upwardly through the channels 56between the settler plates. In one embodiment, the flow of clarifiedliquid 42C into the hollow supports 90 reduces the pressure head by upto approximately 0.5 inches.

One the clarified liquid 42C enters the hollow interior 92 of the hollowsupport 90, the clarified liquid flows laterally out of the hollowsupport. The liquid 42C may then flow over a weir and into a trough. Thetrough can then direct the clarified liquid 42C out of the detentionbasin 4.

Referring now to FIG. 16 , a blank 110 of an embodiment of the presentdisclosure is generally illustrated. The blank 110 can be formed into asettler plate 60 of the embodiments described in conjunction with FIGS.11-15 of the present disclosure. More specifically, the blank 110 can beused to form a settler plate 60 from a single piece of material andwithout welding additional material to the settler plate.

In one embodiment, the blank 110 is formed of a 20 to 26 gauge material,or a 24 gauge material. The material of the blank 110 can be a stainlesssteel alloy, such as a 304 stainless steel alloy. Alternatively, theblank can be formed of carbon steel, aluminum, or bendable plastic, suchas Acrylonitrile butadiene styrene (ABS). The blank 110 can have alength of between approximately 90 inches and approximately 140 inches,or approximately 124 inches. A width of the blank can be betweenapproximately 40 inches and approximately 80 inches, or about 60 inches.The blank 110 is generally planar.

The blank 110 generally includes a central sheet 112, a first end tab114, a second end tab 126 and two lateral tabs 132A, 132B. The centralsheet 112 can form a settling surface 62 of a settler plate 60. Notches138 can be formed between the first end tab 114 and the lateral tabs132. Similarly, notches 140 can be formed between the second end tab 126and the lateral tabs. The notches 138, 140 can be provided to facilitatebending of the tabs 114, 126, 132 into predetermined shapes. Ports 82for effluent can optionally be formed in the blank 110. Although theports 82 are illustrated with a circular shape, the ports can have anydesired shaped, including a square or rectangular shape.

A plurality dashed lines are shown. Each dashed line represents an axisof bending, or bend axis, for a location at which the blank can be bentor folded to form the settler plate 60.

The first end tab 114 generally includes one or more bend axes 116, 118,120, 122, 124, and optionally 128. The bend axes indicate locations atwhich the first end tab 114 can be bent to form a hollow support 90,such as generally illustrated in FIG. 15E. More specifically, the axes116-124 and 128 generally define the first through sixth segments96A-96F of the hollow support 90.

Optionally, one or more orifices 98 can be formed in the first end tab114. In one embodiment, at least one orifice 98 is formed between thesecond bend axis 118 and the third bend axis 120.

In one embodiment, positions 144 for fasteners, such as rivets, areindicated on the first end tab 114. The fastener positions 144 may bebetween the first and second bend axis 116, 118 and between the fifthand sixth bend axis 124, 128. Optionally, the fastener positions 144 maybe a hole through the blank 110.

The hollow support 90 can be formed by bending the first end tab 114proximate to the bend axes 116-124 and 128. Any bending or foldingapparatus can be used. One example of a suitable folding machine thatcan be used to form a blank 110 into a settler plate 60 is an RASXLTbend. Other suitable folding machines are known to those of skill inthe art.

In one embodiment, the hollow support 90 of the embodiment generallyillustrated in FIG. 15E is formed by bending an outer portion of thefirst end tab 114 around the sixth axis 128 to define the sixth segment96F. The first end tab 114 can be bent or folded upwardly at an angle ofapproximately 35° at the six axis 128.

The first end tab 114 is then bent upwardly by approximately 90° at thefifth bend axis. In this manner, the fifth segment 96E is formed.

The first end tab 114 can also be bent or folded at the fourth axis 122to define the fourth segment 96D. Optionally, the first end tab 114 isbent or folded upwardly at an angle of approximately 118° at the fourthaxis 122. Similarly, the first end tab 114 can be bent or folded at thethird axis 120, the second axis 118, and the first axis 116 to form thethird segment 96C, second segment 96B, and the first segment 96A. Thefirst end tab 114 can be bent by approximately 62° at the third axis120, approximately 90° at the second axis 118, and approximately 35° atthe first axis 116. In one embodiment, each bend 116, 118, 120, 122,124, and 128 has a radius of curvature of approximately 1/16th inch. Thebending or folding at the bend axes 116-124 and 128 can be performed inone or more operations.

The second end tab 126 can be formed into a stiffening feature 70 ofembodiments of the present disclosure. In one embodiment, the second endtab 126 can be bent or folded down and approximately in half at theeighth bend axis 134, or by approximately 180°. Optionally, the secondend tab 126 can be folded in half one or more additional times. Thesecond end tab 126 can next be bent or folded downwardly byapproximately 44° at the seventh bend axis 130. In this manner, thestiffening feature 70 of the embodiment illustrated in FIG. 15F can beformed. In one embodiment, the second end tab 126 can first be bent atthe ninth bend axis 136 to form a flange 71. In one embodiment, thesecond end tab 126 is bent two or more times to form the stiffeningfeature 70.

The lateral tabs 132 can be bent one or more times to form baffles 74 ofembodiments of the present disclosure. More specifically, the lateraltabs 132 can be bent or folded by approximately 90° at the tenth axis146 to define the baffles 74 of the present disclosure. In oneembodiment, the lateral tabs 132 are bent or folded by approximately 90°at the eleventh axis 148 to form flanges 78 extending inwardly from thebaffles 74.

While various embodiments of the system have been described in detail,it is apparent that modifications and alterations of those embodimentswill occur to those skilled in the art. It is to be expressly understoodthat such modifications and alterations are within the scope and spiritof the present disclosure. Further, it is to be understood that thephraseology and terminology used herein is for the purposes ofdescription and should not be regarded as limiting.

To provide additional background, context, and to further satisfy thewritten description requirements of 35 U.S.C. § 112, the followingreferences are incorporated by reference herein in their entireties:U.S. Pat. Nos. 3,963,624; 4,089,782; 4,120,796; 4,136,012; U.S. Pat.Nos. 4,157,969; 4,221,671; 4,889,624; 5,049,278; U.S. Pat. Nos.5,116,443; 5,378,378; 5,391,306; 6,245,243; 6,783,009; 6,971,398;7,314,572; 7,850,860; 8,585,896; 8,945,401; 9,327,999; 9,656,188;9,993,747; U.S. Pat. Pub. 2008/0314823; U.S. Pat. Pub. 2012/0312741; andU.S. Pat. Pub. 2017/0050124.

What is claimed is:
 1. An apparatus for clarifying liquid in whichsolids are suspended, comprising: a frame; and a plurality of settlerplates spaced along a longitudinal axis of the frame to define aplurality of channels, each of the settler plates including: a settlingsurface; a back surface; a baffle at a lateral side of the settlingsurface, the baffle extending upwardly above the settling surface; astiffening feature at a lower end; and a hollow support proximate to anupper end that is integrally formed with the settling surface, thehollow support extending upwardly above the settling surface andincluding a hollow interior and an orifice for liquid flowing upwardlyfrom a channel to enter into the hollow interior, the hollow interior todirect liquid laterally to a trough.
 2. The apparatus of claim 1,wherein the hollow support further comprises: a first segment extendingfrom the settling surface; a second segment extending from the firstsegment; a third segment extending from the second segment toward thebaffle; a fourth segment extending from the third segment and proximateto an end of the baffle; and a fifth segment extending from the fourthsegment, wherein the fifth segment extends along a portion of the firstsegment.
 3. The apparatus of claim 2, wherein the second segment isapproximately perpendicular to the first segment, wherein the fourthsegment is approximately parallel to the second segment, and wherein thefifth segment is approximately parallel to the first segment.
 4. Theapparatus of claim 2, wherein a fastener extends through the first andfifth segments.
 5. The apparatus of claim 2, wherein the orifice extendsthrough the second segment.
 6. The apparatus of claim 2, wherein aninterior angle between the settling surface and the first segment isbetween approximately 130° and approximately 160°.
 7. The apparatus ofclaim 1, wherein the hollow support does not intersect a plane definedby the back surface.
 8. The apparatus of claim 1, wherein the settlerplate and the hollow support are formed from a single piece of astainless steel alloy without welding.
 9. The apparatus of claim 1,wherein the baffle includes a flange that extends above the settlingsurface, and wherein a flange of a first settler plate contacts a backsurface of a second adjacent settler plate.
 10. The apparatus of claim9, wherein the baffle includes a port formed proximate to a lower end ofthe baffle, the port having a shape that is generally circular,rectangular, or square.
 11. The apparatus of claim 1, wherein thesettler plates are inclined at an angle of between approximately 50° andapproximately 60° relative to the longitudinal axis of the frame.
 12. Asettler plate, comprising: a settling surface that is substantiallyrectangular; a back surface opposite to the settling surface; a baffleat a lateral side of the settler plate; a stiffening feature at a lowerend of the settler plate; and a hollow support at an upper end of thesettler plate, the hollow support extending from the settling surfaceand including: a hollow interior to transport liquid laterally; a widththat is greater than a width of the settling surface; and an orifice forliquid to enter the hollow support.
 13. The settler plate of claim 12,wherein the hollow support is integrally formed with the settler plate.14. The settler plate of claim 12, wherein the settler plate is formedfrom a single piece of a stainless steel alloy.
 15. The settler plate ofclaim 12, wherein the baffle extends upwardly above the settlingsurface.
 16. The settler plate of claim 12, wherein the hollow supportis formed by bending a piece of the settler plate at least four times.17. The settler plate of claim 12, wherein the hollow support comprisesa first segment extending from the settling surface, wherein an interiorangle between the settling surface and the first segment is betweenapproximately 130° and approximately 160°.
 18. The settler plate ofclaim 17, wherein the hollow support further comprises: a second segmentextending from the first segment, the second segment orientedapproximately perpendicular to the first segment; a third segmentextending from the second segment toward the baffle; a fourth segmentextending from the third segment and proximate to an end of the baffle,the fourth segment oriented approximately parallel to the secondsegment; and a fifth segment extending from the fourth segment, whereinthe fifth segment is joined to the first segment by a fastener.
 19. Amethod of forming a settler plate, comprising: providing a blank of ametallic material, the blank including a first end tab, a second endtab, and lateral tabs; bending the first end tab at least two times toform a hollow support that extends from a settling surface of thesettler plate; bending the second end tab at least two times to form astiffening feature at a lower end of the settler plate; and bending thelateral tabs upwardly to form a baffle at each lateral side of thesettler plate, the baffles extending above the settling surface.
 20. Themethod of claim 19, further comprising: bending the first end tabupwardly approximately 35° to form a first segment of the hollowsupport, the first segment extending from the settling surface; bendingthe first end tab upwardly approximately 90° to form a second segment ofthe hollow support that extends from the first segment; bending thefirst end tab upwardly approximately 62° to form a third segment of thehollow support that extends from the second segment; and bending thefirst end tab upwardly approximately 118° to form a fourth segment ofthe hollow support that extends from the third segment.